Precise Prediction of Near-Net-Shape HIP Components through DEM and FEM Modelling

Precise Prediction of Near-Net-Shape HIP Components through DEM and FEM Modelling

Yuanbin Deng, Anke Kaletsch, Alexander Bezold, Christoph Broeckmann

Abstract. In Hot Isostatic Pressing (HIP) of metal powder, anisotropic shrinkage of the capsule induced by inhomogeneity of the initial powder filling density determines the reproducible realization of small geometrical allowances. This becomes a detrimental factor in the manufacturing of near-net-shape components due to their high requirements for the final shape accuracy. This challenge can be solved by precisely predicting and controlling the shrinkage with respect to the filling density via numerical simulation. Using Discrete-Element-Method (DEM), a three-dimensional initial powder density distribution of the whole component is simulated. After being validated by experimental results from metallographic examination, the calculated powder density distribution is mapped to a Finite-Element (FE) model. An in-house developed user defined material (UMAT) Subroutine, which considers both instantaneous plasticity at lower temperatures and rate dependent plasticity at higher temperatures, is utilized for the simulation with ABAQUS. The preliminary experimental validation using lab scale component reveals that the shrinkage induced shape changes during HIP can be accurately predicted by iterative simulations. Furthermore, the influences of local density distribution during HIP are also investigated. In summary, the developed simulation method demonstrates high accuracy in HIP component shape prediction. Therefore, the method can be easily used for designing HIP capsules for large and complex components.

Keywords
Hot Isostatic Pressing (HIP), Discrete-Element-Method (DEM), Powder Filling, Finite-Element-Method (FEM), Powder Densification, Modelling, Simulation

Published online 2/11/2019, 8 pages
Copyright © 2019 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: Yuanbin Deng, Anke Kaletsch, Alexander Bezold, Christoph Broeckmann, Precise Prediction of Near-Net-Shape HIP Components through DEM and FEM Modelling, Materials Research Proceedings, Vol. 10, pp 182-189, 2019

DOI: https://dx.doi.org/10.21741/9781644900031-24

The article was published as article 24 of the book Hot Isostatic Pressing

Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.

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