Simulation of laser impact welding for dissimilar additively manufactured foils considering influence of inhomogeneous microstructure
Simulation of laser impact welding for dissimilar additively manufactured foils considering influence of inhomogeneous microstructure
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DOI：
10.1016/j.matdes.2020.109372
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发表时间：
2021
影响因子：
8.4
通讯作者：
Sumair Sunny;Glenn Gleason;Ritin Mathews;A. Malik
中科院分区：
文献类型：
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作者：
Sumair Sunny;Glenn Gleason;Ritin Mathews;A. Malik
介绍了一个全面的数值模拟框架，包括微观组织时，模拟金属的激光冲击焊接（LIW）研究焊缝成形过程中发生的瞬态现象。这种瞬态现象包括剪应力、塑性应变、热响应和材料喷射的演变。首先使用动态动力学蒙特卡罗（KMC）方法预测两种不同箔（铝1100和不锈钢304）的非均匀微观结构，以模拟基于激光的粉末床熔合（PBF-LB）增材制造（AM）。这些微观结构随后被纳入到一个欧拉有限元（FE）模拟的LIW过程中，使预测晶粒伸长率，从不同的屈服面，堆垛层错能，晶界滑动效应的结果。在预测的微观结构变形模式的趋势显示出强烈的一致性与文献中的实验图像。与现有的均匀模型相比，新的框架与不均匀的AM微观结构揭示了更高的碰撞速度在焊缝界面处，从而增加塑性应变速率，更大的塑性散热，并增加材料喷射与更高的喷射温度。该框架允许新的机会来研究晶粒形貌（以及多晶金属织构）和冲击焊接界面处发生的瞬态过程现象之间的相关性。
Introduced is a comprehensive numerical modeling framework that includes microstructure when simulating the laser impact welding (LIW) of metals to study the transient phenomena that occur during weld formation. Such transient phenomena include evolution of shear stresses, plastic strains, thermal response, and material jetting. Inhomogeneous microstructures for two dissimilar foils (aluminum 1100 and stainless steel 304) are first predicted using the Dynamic Kinetic Monte Carlo (KMC) method to simulate laser-based powder bed fusion (PBF-LB) additive manufacturing (AM). These microstructures are subsequently incorporated into an Eulerian finite element (FE) simulation of the LIW process, enabling prediction of grain elongations that result from the varying yield surfaces, stacking fault energies, and grain-boundary sliding effects. Trends in the predicted microstructure deformation patterns show strong agreement with those from experimental images in the literature. Compared to existing homogeneous models, the new framework with inhomogeneous AM microstructure reveals higher collision velocities at the weld interface, resulting in increased plastic strain rates, greater plastic heat dissipation, and increased material jetting with higher jet temperatures. The framework allows for new opportunities to study correlations between grain topography (as well as polycrystalline metal texture) and the transient process phenomena occurring at the impact weld interface.