Analysis of Thermo-mechanical Characteristics of LENS Process for Steels Using the Finite Element Method

Pratt, P. (2009). Analysis of Thermo-mechanical Characteristics of LENS Process for Steels Using the Finite Element Method. ProQuest/UMI.

Abstract

Laser Engineered Net Shaping (LENS™) is a rapid-manufacturing procedure that involves complex thermal, mechanical, and metallurgical interactions. The finite element method (FEM) may be used to accurately model this process, allowing for optimized selection of input parameters, and, hence, the fabrication of components with improved thermo-mechanical properties. In this study the commercial FEM code SYSWELD® is used to predict the thermal histories and residual stresses generated in LENS™-produced thin plates of AISI 410 stainless steel built by varying the process parameters laser power and stage translation speed. The computational results are compared with experimental measurements for validation, and a parametric study is performed to determine how the thermo-mechanical properties vary with these parameters. Thermal calculations are also performed with the code ABAQUS® to evaluate its potential use as a modeling tool for the LENS™ process.