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Research Papers

Effects of Interpass Idle Time on Thermal Stresses in Multipass Multilayer Weld-Based Rapid Prototyping

[+] Author and Article Information
Huihui Zhao

State Key Laboratory of Advanced
Welding and Joining,
Harbin Institute of Technology,
Harbin 150001, PRC;
Shanghai Aerospace Equipments Manufacturer,
Shanghai 200245, PRC

Guangjun Zhang

e-mail: zhanggj@hit.edu.cn

Lin Wu

State Key Laboratory of Advanced
Welding and Joining,
Harbin Institute of Technology,
Harbin 150001, PRC

1Corresponding author.

Contributed by the Manufacturing Engineering Division of ASME for publication in the Journal of Manufacturing Science and Engineering. Manuscript received September 1, 2011; final manuscript received December 31, 2012; published online January 29, 2013. Assoc. Editor: Wei Li.

J. Manuf. Sci. Eng 135(1), 011016 (Jan 29, 2013) (6 pages) Paper No: MANU-11-1289; doi: 10.1115/1.4023363 History: Received September 01, 2011; Revised December 31, 2012

Interpass idle time is an important parameter affecting the thermal stress distribution in weld-based rapid prototyping. In this paper, the effects of interpass idle time on thermal stresses in multipass multilayer weld-based rapid prototyping are investigated using numerical simulation. Meanwhile the single-layer weld-based rapid prototyping experiment is carried out, and the residual stresses are measured in the blind-hole method. The variation trend of calculated residual stresses agrees with that of experimental measurements. The research results indicate that there exist stress release effects of rear pass on fore passes and that of rear layer on fore layers. The interpass and interlayer stresses and residual stresses are significantly dependent on interpass idle time. The residual stresses of deposition workpiece decrease with the increase of interpass idle time, whereas the interpass and interlayer stresses on the central line of substrate increase with the increase of interpass idle time.

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Figures

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Fig. 1

Deposition workpiece and measuring locations of residual stresses. (a) Weld-based rapid prototyping workpiece. (b) Locations of strain gauges.

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Fig. 2

Three-dimensional finite element models. (a) Ten-pass single-layer model. (b) Multipass multilayer model.

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Fig. 3

Calculated and experimental residual stress along GH. (a) Transversal stresses σx. (b) Longitudinal stresses σz.

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Fig. 4

Interpass longitudinal stress distribution with different interpass idle time. (a) Continuous deposition. (b) Deposition with idle time 33 s between two adjacent passes of depositing. (c) Cooling to room temperature after every pass.

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Fig. 5

Interlayer stress distribution with different interpass idle time. (a) Continuous deposition. (b) Deposition with idle time 33 s between two adjacent passes of depositing. (c) Cooling to room temperature after every pass.

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Fig. 6

Residual stress distribution of workpiece with different interpass idle time. (a) Continuous deposition. (b) Deposition with idle time 33 s between two adjacent passes of depositing. (c) Cooling to room temperature after every pass.

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