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CASiM² project: Simulation of Additive Manufacture

Researcher(s): ,  Yogesh Sovani

Collaborator(s): Moataz Attallah, Mark Ward, Jeff Brooks, Hector Basoalto

Additive layer manufacturing is a rapid fabrication process in which three-dimensional metal structures are built layer by layer from computer aided designs. Application of additive layer manufacturing (ALM) process extends from coating to fabrication as well as in repairing of three-dimensional complex shaped parts. In particular, the ALM process facilitates manufacturing of component to its near final shape directly from the CAD model reducing the lead time between the conceptual stage and the manufacturing of the final component.

A highly transient nature of the ALM due to the rapid melting and solidification causes distortion and residual stresses, affecting both the dimensional accuracy of parts and the resulting mechanical properties. To guarantee an optimised design of ALM process, it is of high interest to predict the distortion and residual stress within the part. A computational model for the additive layer manufacturing would allow greater understanding of the temperatures experienced, the residual stresses generated and the distortions induced by the process. 

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