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Residual stress analysis of TC4/Inconel718 functionally graded material produced by laser additive manufacturing based on progressive activation element method

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Abstract

With the continuous development of preparation technology, laser additive manufacturing (LAM) has become one of the effective ways to manufacture functionally graded materials due to its unique layer-by-layer stacking technology. However, the repeated and repeated rapid heating and cooling processes in the manufacturing process will generate large residual stress inside the structure, resulting in the destruction of the structure. In this paper, based on a new finite element method called progressive activation element (PAE), a thermo-mechanical coupling model for simulating the process of LAM is established, and the influence of laser power and composition ratio of transition layers on the residual stress of the overall structure is discussed. The results show that there is a positive correlation between the laser power and the residual stress. The PAE method is compared with the traditional “Model Change” method, and it is found that the PAE method has advantages in computational efficiency, especially when calculating the residual stress of functionally graded materials; the efficiency can be improved by about 1650%. When the TC4/Inconel718 functionally graded material is prepared experimentally, the optimal composition ratio of the transition layers is 8:2. This paper provides reference for the understanding and reasonable suppression of residual stress of functionally graded materials in LAM.

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Author contributions

The work presented here was performed in collaboration among all authors. Hongjian Zhao designed, analyzed, and wrote the paper. Chi Gao, Zihao Wang, Quanyi Wang, Changsheng Liu and Yu Zhan provided and analyzed the experimental data. All authors contributed to and approved the manuscript.

Hongjian Zhao (first author): conceptualization, methodology, software, validation, formal analysis, investigation, writing—original draft

Chi Gao: formal analysis, writing—original draft

Zihao Wang: software, formal analysis

Quanyi Wang: validation

Changsheng Liu: resources, supervision, funding acquisition

Yu Zhan (corresponding author): visualization, resources, writing—review and editing, funding acquisition

Funding

This study is supported by the National Natural Science Foundation of China Project (Grant No. 51771051), the Natural Science Foundation of Liaoning Province Project (Grant No. 2021-MS-102), the Fundamental Research Funds for the Central Universities (Grant No. N2105021), and the National Training Program of Innovation and Entrepreneurship for Undergraduates (Grant No.230033).

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Authors and Affiliations

  1. College of Sciences, Northeastern University, Shenyang, 110819, China

    Hongjian Zhao, Zihao Wang, Quanyi Wang & Yu Zhan

  2. School of Mechanical and Aerospace Engineering, Jilin University, Changchun, 130025, China

    Chi Gao

  3. Key Laboratory for Anisotropy and Texture of Materials Ministry of Education, Northeastern University, Shenyang, 110819, China

    Changsheng Liu

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  1. Hongjian Zhao
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Correspondence to Yu Zhan.

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Zhao, H., Gao, C., Wang, Z. et al. Residual stress analysis of TC4/Inconel718 functionally graded material produced by laser additive manufacturing based on progressive activation element method. Int J Adv Manuf Technol 129, 1443–1453 (2023). https://doi.org/10.1007/s00170-023-12348-3

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  • DOI: https://doi.org/10.1007/s00170-023-12348-3

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