Optimizing Laser Powder Bed Fusion Parameters for IN-738LC by Response Surface Method.

A method to find the optimum process parameters for manufacturing nickel-based superalloy Inconel 738LC by laser powder bed fusion (LPBF) technology is presented. This material is known to form cracks during its processing by LPBF technology; thus, process parameters have to be optimized to get a high quality product. In this work, the objective of the optimization was to obtain samples with fewer pores and cracks. A design of experiments (DoE) technique was implemented to define the reduced set of samples. Each sample was manufactured by LPBF with a specific combination of laser power, laser scan speed, hatch distance and scan strategy parameters. Using the porosity and crack density results obtained from the DoE samples, quadratic models were fitted, which allowed identifying the optimal working point by applying the response surface method (RSM). Finally, five samples with the predicted optimal processing parameters were fabricated. The examination of these samples showed that it was possible to manufacture IN738LC samples free of cracks and with a porosity percentage below 0.1%. Therefore, it was demonstrated that RSM is suitable for obtaining optimum process parameters for IN738LC alloy manufacturing by LPBF technology.

Improvement in determining the risk of damage to the human lumbar functional spinal unit considering age, height, weight and sex using a combination of FEM and RSM.

Human functional spinal unit (FSU) is comprised of two adjacent vertebrae, the intervertebral disc (IVD), the cartilage endplates and the connecting ligamentous tissues. As humans age, trabecular, cortical bone and IVD change in mechanical properties. These changes influence the movement of the FSU (displacements, rotations and disc bulges). This paper proposes a method to determine the influence of sex, age, weight and height on the movements of the FSU using a combination of the FEM and RSM. The work concentrates on the medium-sized human FSU (L3-L4 lumbar level with standard dimensions of IVD: width = 50 mm, depth = 35 mm and height = 11 mm). Also, the proposed method could be an improvement to the determination of risk of damage based on body mass index (BMI), as well as an alternative method of searching for a healthy weight. The method was developed as follows: First, a three-dimensional parameterized human healthy FSU FE model was generated based on the standard test (for compression, flexion, extension, lateral bending, torsion and shear). The movements of the FSU FE model based on the aforementioned standardized test when the sex, age, weight and height varies in a range for each individual (30-80 years; 70-120 kg; 160-190 cm) were simulated. Quadratic regression models were generated for each standardized test using RSM. An ANOVA test showed that all of the tests have a significant influence on weight and age, whereas height influences only those tests that involve rotation of the FSU (flexion, extension and lateral bending). Normal weight, overweight and obesity BMI classifications were considered in determining the healthy weight with the following constraints: the limit angles of flexion and lateral bending, as well as the maximum posterior bulge limit of the IVD, could not exceed of one-third of the spinal canal. The proposed method concluded that: (1) normal BMI values do not cause damage to the FSU, (2) some overweight BMI values may cause damage to the FSU for a certain range of ages and heights and (3) for BMI obesity values, the risk of damage to the FSU may be imminent.

Finite Element Model Updating Combined with Multi-Response Optimization for Hyper-Elastic Materials Characterization.

The experimental stress-strain curves from the standardized tests of Tensile, Plane Stress, Compression, Volumetric Compression, and Shear, are normally used to obtain the invariant λi and constants of material Ci that will define the behavior elastomers. Obtaining these experimental curves requires the use of expensive and complex experimental equipment. For years, a direct method called model updating, which is based on the combination of parameterized finite element (FE) models and experimental force-displacement curves, which are simpler and more economical than stress-strain curves, has been used to obtain the Ci constants. Model updating has the disadvantage of requiring a high computational cost when it is used without the support of any known optimization method or when the number of standardized tests and required Ci constants is high. This paper proposes a methodology that combines the model updating method, the mentioned standardized tests and the multi-response surface method (MRS) with desirability functions to automatically determine the most appropriate Ci constants for modeling the behavior of a group of elastomers. For each standardized test, quadratic regression models were generated for modeling the error functions (ER), which represent the distance between the force-displacement curves that were obtained experimentally and those that were obtained by means of the parameterized FE models. The process of adjusting each Ci constant was carried out with desirability functions, considering the same value of importance for all of the standardized tests. As a practical example, the proposed methodology was validated with the following elastomers: nitrile butadiene rubber (NBR), ethylene-vinyl acetate (EVA), styrene butadiene rubber (SBR) and polyurethane (PUR). Mooney⁻Rivlin, Ogden, Arruda⁻Boyce and Gent were considered as the hyper-elastic models for modeling the mechanical behavior of the mentioned elastomers. The validation results, after the Ci parameters were adjusted, showed that the Mooney⁻Rivlin model was the hyper-elastic model that has the least error of all materials studied (MAEnorm = 0.054 for NBR, MAEnorm = 0.127 for NBR, MAEnorm = 0.116 for EVA and MAEnorm = 0.061 for NBR). The small error obtained in the adjustment of the Ci constants, as well as the computational cost of new materials, suggests that the methodology that this paper proposes could be a simpler and more economical alternative to use to obtain the optimal Ci constants of any type of elastomer than other more sophisticated methods.