PSI - Issue 34

Available online at www.sciencedirect.com Structural Integrity Procedia 00 (2019) 000 – 000 Available online at www.sciencedirect.co ci c ir ct Structural Integrity Procedia 00 (2019) 000 – 000 Available online at www.sciencedirect.com ScienceDirect

www.elsevier.com/locate/procedia www.elsevier.com/locate/procedia

ScienceDirect

Procedia Structural Integrity 34 (2021) 235–246

© 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers Abstract As virtual manufacturing in additive manufacturing (AM) becomes more mature, the benefits of using this technology increases. Virtual manufacturing simulations often capture only one step in the AM process chain decoupled from the subsequent steps. However, all steps in the process chain influence the final product in their own way. Therefore, this study focusses on the development of a virtual manufacturing framework to perform sequential process simulations of the complete process chain for AM parts. This framework can ultimately be used to obtain insights on the effect of additional processes or process variations on the final product. In this study, the framework is used to obtain insights on the effect of residual stress due to the laser metal deposition (LMD) process on the fatigue life of the final part. To this end, a calibration and validation of a part-scale LMD process simulation is performed to obtain deformations and residual stresses. This is followed by a heat treatment simulation to determine the effect of post heat treatment on the deformation and residual stresses of the final part. By combining the residual stress field with fatigue loads, the effect of different process steps on the fatigue life is investigated. © 2020 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers Keywords: Metal Additive Manufacturing; Virtual Manufacturing; Process Chain; Fatigue Life Prediction he second uropean onference on the Structural Integrity of dditively anufactured aterials ll r ss i si l ti f t ( ir - s ) l s r t l siti r ss t r s f ti lif r i ti i oenis a* , outer van den rink a , arko os an b a Royal Netherlands Aerospace Centre (NLR), Amsterdam, The Netherlands b GKN Aerospace, Papendrecht, The Netherlands Abstract As virtual manufacturing in additive manufacturing (A ) becomes more mature, the benefits of using this technology increases. Virtual manufacturing simulations often capture only one step in the A process chain decoupled from the subsequent steps. However, all steps in the process chain influence the final product in their own way. Therefore, this study focusses on the development of a virtual manufacturing framework to perform sequential process simulations of the complete process chain for A parts. This framework can ultimately be used to obtain insights on the effect of additional processes or process variations on the final product. In this study, the framework is used to obtain insights on the effect of residual stress due to the laser metal deposition (L D) process on the fatigue life of the final part. To this end, a calibration and validation of a part-scale L D process simulation is performed to obtain deformations and residual stresses. This is followed by a heat treatment simulation to determine the effect of post heat treatment on the deformation and residual stresses of the final part. By combining the residual stress field with fatigue loads, the effect of different process steps on the fatigue life is investigated. © 2020 The uthors. Published by ELSEVIER B.V. This is an open access article under the CC B - C- license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-revie under responsibility of the scientific co ittee of the Esia organisers Keywords: etal Additive anufacturing; Virtual anufacturing; Process Chain; Fatigue Life Prediction The second European Conference on the Structural Integrity of Additively Manufactured Materials Full process chain simulation of the (wire-based) laser metal deposition process towards fatigue life prediction Tim Koenis a* , Wouter van den Brink a , Marko Bosman b a Royal Netherlands Aerospace Centre (NLR), Amsterdam, The Netherlands b GKN Aerospace, Papendrecht, The Netherlands

* Corresponding author. Tel.: +31-88-511-47-04. E-mail address: tim.koenis@nlr.nl * Corresponding author. Tel.: +31-88-511-47-04. E-mail address: tim.koenis nlr.nl

2452-3216 © 2020 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers 2452-3216 © 2020 The Authors. Published by ELSEVIER B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers

2452-3216 © 2021 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (https://creativecommons.org/licenses/by-nc-nd/4.0) Peer-review under responsibility of the scientific committee of the Esiam organisers 10.1016/j.prostr.2021.12.034