
Fabrication Orientation Sequence Optimization for Controlling Mechanical Properties in Metal Additive Manufacturing
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In Large-scale metal Additive Manufacturing (AM), commonly called directed energy deposition, the deposited material is subjected to a series of heating and cooling cycles throughout the AM process. The locally occurring temperature extremes and cooling rates determine solid-state phase fractions, material microstructure, texture, and ultimately the local material properties, including strength, ductility, and hardness [1]. One type of directed energy deposition is wire arc additive manufacturing, where a robotic arm facilitates the molten material deposition, and rotational movement of the part during fabrication can be realized using turntables. This capability introduces a novel opportunity to rotate the part and change the printing orientation instead of printing the entire part with a fixed direction. Since printing direction affects the local thermal evolution, it can also be used to control the local mechanical properties. This is possible by dividing the part into several sub-parts, each with its unique printing direction, referred to as fabrication orientation sequence planning. This study presents a mathematical optimization formulation of the fabrication sequence for achieving the desired mechanical properties at critical design locations during the AM process. The printing orientation of each sub-part becomes a design variable, and along with a pseudo-time, the printing process can be simulated. For any design iteration, we solve the transient heat equation for the corresponding fabrication sequence. Based on the temperature transients computed, an analytical microstructure model predicts material properties such as yield strength [2]. We employ a gradient-based optimization approach to optimize the orientation variables, constraining the mechanical properties at critical design locations. We will present the optimized fabrication sequence for various complex design cases relevant to AM applications.