金属增材制造(AM)能够生产复杂的零件,使用广泛的功能金属,否则很难制造,并涉及多个制造过程。然而,由于金属AM零件的制造涉及热能,残余应力仍然是金属AM的主要关注点之一。这种残余应力对零件质量有负面影响,尺寸精度,和部分性能。本研究旨在对残余应力的不同方面进行全面的回顾和分析,包括金属AM过程中残余应力产生的原因和机制,用于测量残余应力的最先进的测量技术,影响残余应力的各种因素,它对零件质量和性能的影响,以及最小化或克服金属AM零件中的残余应力的方法。残余应力形成机制各不相同,基于3D打印工艺的逐层沉积机理。例如,线弧增材制造的残余应力形成不同于选择性激光烧结,直接能量沉积,和粉末床融合过程。残余应力形成机制也根据尺度而变化(即,宏,micro,等。)在此执行打印。此外,印刷参数与残余应力的形成存在相关性。例如,打印方向,层厚度,内部结构,等。,影响残余应力的形成机制和定量值。残余应力对打印部件的质量的主要影响在于部件的变形。此外,尺寸精度,表面光洁度,打印件的疲劳性能受到残余应力的影响。这篇综述论文对地层进行了定性和定量分析,分布,以及不同金属AM工艺的残余应力演变。本文还讨论和分析了测量残余应力的原位和非原位测量技术。分析了显微组织演变及其对残余应力形成的影响。详细讨论了用于应对残余应力的各种预处理和后处理技术。最后,本研究旨在提出一个定性和定量分析的现有数据和技术在相关的文献中,残余应力,并为未来的研究方向提供批判性分析和指导方针,以防止或克服金属AM工艺中的残余应力形成。
Metal additive manufacturing (AM) is capable of producing complex parts, using a wide range of functional metals that are otherwise very difficult to make and involve multiple manufacturing processes. However, because of the involvement of thermal energy in the fabrication of metallic AM parts, residual stress remains one of the major concerns in metal AM. This residual stress has negative effects on part quality, dimensional accuracy, and part performance. This study aims to carry out a comprehensive
review and analysis of different aspects of residual stress, including the causes and mechanisms behind the generation of residual stress during metal AM, the state-of-the-art measurement techniques for measuring residual stress, various factors influencing residual stress, its effect on part quality and performance, and ways of minimizing or overcoming residual stress in metal AM parts. Residual stress formation mechanisms vary, based on the layer-by-layer deposition mechanism of the 3D printing process. For example, the residual stress formation for wire-arc additive manufacturing is different from that of selective laser sintering, direct energy deposition, and powder bed fusion processes. Residual stress formation mechanisms also vary based on the scale (i.e., macro, micro, etc.) at which the printing is performed. In addition, there are correlations between printing parameters and the formation of residual stress. For example, the printing direction, layer thickness, internal structure, etc., influence both the formation mechanism and quantitative values of residual stress. The major effect residual stress has on the quality of a printed part is in the distortion of the part. In addition, the dimensional accuracy, surface finish, and fatigue performance of printed parts are influenced by residual stress. This
review paper provides a qualitative and quantitative analysis of the formation, distribution, and evolution of residual stress for different metal AM processes. This paper also discusses and analyzes both in situ and ex situ measurement techniques for measuring residual stress. Microstructural evolution and its effect on the formation of residual stress are analyzed. Various pre- and post-processing techniques used to countermeasure residual stress are discussed in detail. Finally, this study aims to present both a qualitative and quantitative analysis of the existing data and techniques in the literature related to residual stress, as well as to provide a critical analysis and guidelines for future research directions, to prevent or overcome residual stress formation in metal AM processes.