Distortion Prediction in Inconel-718 Part Fabricated through LPBF by Using Homogenized Support Properties from Experiments and Numerical Simulation

The Laser Powder-Bed Fusion (LPBF) process produces complex part geometry by selectively sintering powder metal layer upon layer. During the LPBF process, parts experience the challenge of residual stress, distortions, and print failures. Lattice-based structures are used to support overhang parts and reduce distortion; this lattice support has complex geometry and demands high computational effort to predict distortion using simulation. This study proposes a computational efforts reduction strategy by replacing complex lattice support geometry with homogenization using experimentally determined mechanical properties. Many homogenization models have been established to relate the lattice topology and material properties to the observed mechanical properties, like the Gibson–Ashby model. However, these predicted properties vary from as printed lattice geometry. In this work, the power-law relationship of mechanical properties for additively manufactured Inconel 718 part is obtained using tensile tests of various lattice support topologies and the model is used for homogenization in simulation. The model’s accuracy in predicting distortion in printed parts is demonstrated using simulation results for a cantilever model. Simulation studies show that computational speed is significantly increased (6–7 times) using the homogenization technique without compromising the accuracy of distortion prediction.