Additive Manufacturing and Thermal Analysis of Ti-6Al-4V using ANSYS Software

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Contents
Introduction.................................................................................................................................................3
Project objectives and Deliverables.............................................................................................................4
Objectives............................................................................................................................................4
Deliverables.........................................................................................................................................4
Problem Statement.....................................................................................................................................5
Resource requirements...............................................................................................................................7
Boundary conditions and heat source model......................................................................................8
Research Strategy........................................................................................................................................8
Literature Review......................................................................................................................................12
REFERENCES..............................................................................................................................................16

Introduction
Additive manufacturing commonly known as AM is one of the means of generating complex-
shaped components of metals which are appealing and conforms to the specific applications. A
metallic feedstock that may be in the form of a wire can be possibly be processed to produce a
greater volume by just an application of model data, computer numerical control(CNC), directed
energy and inert atmosphere. Most of the industries including the aerospace, biomedical among
others have taken a keen interest in the use of additive manufacturing in the production of the
tailored products.
Prior to the use of these components, their quality and integrity must be checked and reliably
confirmed. This can be achieved through the determination of the feedstock process property
performance relationship which is normally inherent to the specific material (Yang et al.2016).

By so doing, the same efforts can be expedited through variation of techniques. Considering that
most of the microstructure and macrostructure of the metallic parts of AM process are coupled
directly by the use of heat during their manufacture, the relationship of the process property can
be determined through observation and quantification of the part temperature and other heat
release requirements during the process of Additive Manufacturing.
Powder Bed Fusion is one of the most commonly known methods of AM used in the fabrication
of the components of metals through an application of heat energy followed by a pre-deposition
of a layer that is called a bed of powder feedstock. The source of the energy in the process is
normally generated from a focused laser or beam of the electron. In the case of an application of
the laser, the component or the resultant product is called Laser-BPF. The application of the
radiation of laser that is also localized produces a very high flux of heat which is capable of
overcoming the latent heat of fusion of the powder. The product will, therefore be a micro pool
of the molten substance. As the laser moves away from the already molten point, solidification
begins taking place. The process is actually repeated to assist in the formation of multiple solid
tracks. In this particular paper, there is a proposal in the development of a model of a transient
thermal finite element of a selective laser melting for Ti-6Al-4V by the use of ANSYS software.
This particular software has been recommended for the prediction of thermal history and the size
of the melt pool (Tammas et al.2015). There is remapping of the thermal solution to the
structural problem. This has also been done to assist in the prediction of the induced residual
stress of the items. This particular model that has thermo-mechanical properties is capable of
handling a practical domain size with effective efficiency of computational analysis. This is
achieved through the development of remapping and re-mashing techniques that is capable of
adapting with the scanner vector.