Daniel Riedlbauer

Bio: Daniel Riedlbauer is an academic researcher from University of Erlangen-Nuremberg. The author has contributed to research in topics: Beam (structure) & Finite element method. The author has an hindex of 5, co-authored 8 publications receiving 179 citations.

Macroscopic simulation and experimental measurement of melt pool characteristics in selective electron beam melting of Ti-6Al-4V

Abstract: Selective electron beam melting of Ti-6Al-4V is a promising additive manufacturing process to produce complex parts layer-by-layer additively. The quality and dimensional accuracy of the produced parts depend on various process parameters and their interactions. In the present contribution, the lifetime, width and depth of the pools of molten powder material are analyzed for different beam powers, scan speeds and line energies in experiments and simulations. In the experiments, thin-walled structures are built with an ARCAM AB A2 selective electron beam melting machine and for the simulations a thermal finite element simulation tool is used, which is developed by the authors to simulate the temperature distribution in the selective electron beam melting process. The experimental and numerical results are compared and a good agreement is observed. The lifetime of the melt pool increases linearly with the line energy, whereby the melt pool dimensions show a nonlinear relation with the line energy.

Thermomechanical finite element simulations of selective electron beam melting processes: performance considerations

Abstract: The present contribution is concerned with the macroscopic modelling of the selective electron beam melting process by using the finite element method. The modelling and simulation of the selective electron beam melting process involves various challenges: complex material behaviour, phase changes, thermomechanical coupling, high temperature gradients, different time and length scales etc. The present contribution focuses on performance considerations of solution approaches for thermomechanically coupled problems, i.e. the monolithic and the adiabatic split approach. The material model is restricted to nonlinear thermoelasticity with temperature-dependent material parameters. As a numerical example a straight scanning path is simulated, the predicted temperatures and stresses are analysed and the performance of the two algorithms is compared. The adiabatic split approach turned out to be much more efficient for linear thermomechanical problems, i.e. the solution time is three times less than with the monolithic approach. For nonlinear problems, stability issues necessitated the use of the Euler backward integration scheme, and therefore, the adiabatic split approach required small time steps for reasonable accuracy. Thus, for nonlinear problems and in combination with the Euler backward integration scheme, the monolithic solver turned out to be more efficient.

Realization of Multi-material Polymer Parts by Simultaneous Laser Beam Melting

Abstract: In this paper, first results regarding the realization of multi-material parts by Simultaneous Laser Beam Melting (SLBM) of polymers are presented. This new approach allows the layerwise generation of parts consisting of different polymer materials within one building process. Besides the typical advantages of additive manufacturing technologies, such parts can fulfill different product requirements concomitant and therefore could enlarge the overall field of application. The powder materials used for this paper are polyethylene (PE) and a polyamide based thermoplastic elastomer (TPE). After depositing the powder materials next to each other, infrared-emitters heat the lower melting polymer and a CO2 laser provides the preheating temperature of the higher melting polymer. In the last step, a thulium fibre laser melts the two preheated powders simultaneously. The realized specimens are characterized by cross sections and their tensile strengths are determined. Additionally, the new approach of the simultaneous energy irradiation is investigated using a Finite Element Analysis in order to gain a more profound process understanding. In that sense, the influence of the size of the exposure area on the reachable maximum temperatures inside that area was analyzed by the simulation and compared to experimental studies.

Thermomechanical simulation of the selective laser melting process for PA12 including volumetric shrinkage

Abstract: The present contribution is concerned with the finite element simulation of the thermomechanical material behavior in the selective laser melting process for PA12. In the process shrinkage of the powder material is observed when becoming melt, as the porous character of the powder vanishes due to the phase transition. A nonlinear thermomechanical finite element model is developed, which captures the shrinkage of the material and includes temperature dependent material parameters. The model is used to simulate the shrinkage of the material in the process, where an adaptive mesh refinement is applied for increasing the accuracy of the simulation. The results are qualitatively compared with experimental data and show a good agreement.

Understanding the effect of laser scan strategy on residual stress in selective laser melting through thermo-mechanical simulation

Abstract: Selective laser melting (SLM) is an attractive technology, enabling the manufacture of customised, complex metallic designs, with minimal wastage. However, uptake by industry is currently impeded by several technical barriers, such as the control of residual stress, which have a detrimental effect on the manufacturability and integrity of a component. Indirectly, these impose severe design restrictions and reduce the reliability of components, driving up costs. This paper uses a thermo-mechanical model to better understand the effect of laser scan strategy on the generation of residual stress in SLM. A complex interaction between transient thermal history and the build-up of residual stress has been observed in the two laser scan strategies investigated. The temperature gradient mechanism was discovered for the creation of residual stress. The greatest stress component was found to develop parallel to the scan vectors, creating an anisotropic stress distribution in the part. The stress distribution varied between laser scan strategies and the cause has been determined by observing the thermal history during scanning. Using this, proposals are suggested for designing laser scan strategies used in SLM.

Overview on Additive Manufacturing Technologies

Abstract: This paper provides an overview on the main additive manufacturing/3D printing technologies suitable for many satellite applications and, in particular, radio-frequency components. In fact, nowadays they have become capable of producing complex net-shaped or nearly net-shaped parts in materials that can be directly used as functional parts, including polymers, metals, ceramics, and composites. These technologies represent the solution for low-volume, high-value, and highly complex parts and products.