Author: SETIEN UGALDE, IÑAKI
Thesis file: (contact the
Doctoral School to confirm you have a valid doctoral degree and to get the link to the thesis)
Programme: DOCTORAL DEGREE IN CIVIL ENGINEERING
Department: Barcelona School of Civil Engineering (ETSECCPB)
Mode: Article-based thesis
Deposit date: 10/04/2025
Reading date: 05/06/2025
Reading time: 11:00
Reading place: Campus Nord - UPCCIMNE - Edifici C1 C/ Gran Capità,s/nSala OCZ (Zienkiewicz)08034, Barcelona https://meet.google.com/nvd-fqgp-gsc
Thesis director: CHIUMENTI, MICHELE | SAN SEBASTIÁN ORMAZABAL, MARÍA
Thesis abstract: Metal additive manufacturing (MAM), particularly powder bed fusion using a laser beam (PBF-LB), has transformed manufacturing by enabling the production of intricate and optimised metal components directly from digital designs. This process offers major advantages such as material efficiency, high geometric flexibility, and the ability to produce lightweight, customised parts. However, its industrial adoption is hindered by challenges such as large residual stresses and distortions resulting from steep temperature gradients and rapid thermal cycles inherent in layer-by-layer manufacturing process. These issues compromise dimensional accuracy and structural integrity, posing barriers to the broader implementation of the technology.High-fidelity thermo-mechanical finite element (FE) simulations can predict these phenomena but their high computational cost makes them impractical for large-scale industrial applications. The inherent strain method (ISM) has emerged as an efficient alternative, condensing complex thermal and mechanical phenomena into an inherent strain tensor applied in simplified elastic simulations. While ISM significantly reduces computational time, conventional implementations often lack robustness, requiring extensive recalibration for different geometries and scanning strategies and failing to capture spatial and temporal variations in thermal histories.This thesis addresses these limitations by developing an enhanced inherent strain method (EISM) for powder bed fusion (PBF), improving ISM's predictive accuracy and extending its applicability to complex industrial geometries. By integrating a macro-scale thermal analysis into ISM, the method dynamically refines the precomputed inherent strain tensor based on part-scale temperature evolution. This enhancement better accounts for geometry- and boundary-specific thermal effects, improving distortion predictions compared to conventional ISM.Additionally, this work tackles the fundamental challenge of determining inherent strain tensors necessary for ISM-based methodologies. Two complementary approaches are proposed: (1) an empirical calibration strategy using twin-cantilever beam coupons, where distortions measured after partial cutting are used to determine best-fit inherent strain tensors via inverse engineering, and (2) a numerical approach employing a meso-scale thermo-mechanical model within a multi-scale framework, computing local inherent strains and homogenising them to obtain macro-scale inherent strain tensors.Comprehensive experimental calibration and validation were conducted using Ti-6Al-4V components manufactured via PBF-LB. Temperature histories were recorded with embedded thermocouples, while distortion and residual stress data were acquired using coordinate measuring machines (CMM), 3D scanning, and incremental hole-drilling, respectively. The empirical and numerical methodologies for inherent strain tensor determination, along with EISM, were validated across multiple geometries, including twin-cantilever beams, a non-symmetric bridge, and an industrial aerospace component (the Steady Blowing Actuator). The results demonstrated that EISM significantly improved distortion predictions while maintaining computational efficiency, reducing errors by more than half compared to conventional ISM.In conclusion, this thesis presents two methods for calculating the inherent strain tensor (empirical and numerical) and introduces the EISM methodology for distortion prediction, improving the accuracy of distortion prediction in PBF-LB. In this way, the dependence on trial-and-error-based experimental testing is reduced, moving towards an optimised simulation-based design and facilitating the industrial adoption of MAM.