Document Type
Honors Thesis
Abstract
This study builds a mesoscale finite element simulation to examine how internal stresses form during additive metal manufacturing using directed energy deposition. The goal is to track how heat and stress develop layer by layer and determine where a failure criterion could appear during the print. The model uses temperature-dependent material properties for Inconel 718 and a moving heat source defined with custom G-code.
Thermal results are mapped into a mechanical simulation to watch stress accumulate as new layers are added. Different scan paths were tested to determine whether varying heat exposure could reduce the extent of a region exceeding the ultimate tensile stress. The deformation pattern changed, but the maximum internal stress
remained nearly the same. Since visual inspection can easily miss the moment when failure actually occurs, the study shows that a numerical approach is needed to detect the exact time the failure threshold is reached.
Disciplines
Computer-Aided Engineering and Design | Manufacturing | Other Mechanical Engineering
Publication Date
Fall 12-27-2025
Language
English
Faculty Mentor of Honors Project
Shiyao Lin
License
This work is licensed under a Creative Commons Attribution-NonCommercial-No Derivative Works 4.0 International License.
Recommended Citation
Ramirez, Jachin J., "VIRTUAL PROCESS MODELING OF METAL ADDITIVE MANUFACTURING BASEDON DIRECT ENERGY DEPOSITION IN-SITU FAILURE" (2025). 2025 Fall Honors Capstones Projects-Archive. 34.
https://mavmatrix.uta.edu/honors_fall2025/34
Included in
Computer-Aided Engineering and Design Commons, Manufacturing Commons, Other Mechanical Engineering Commons