David De Baere

David De Baere
Technical University of Denmark | DTU · Department of Mechanical Engineering

PhD

About

10
Publications
5,935
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88
Citations
Citations since 2017
10 Research Items
88 Citations
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Publications

Publications (10)
Article
Full-text available
Laser-based powder bed fusion of 300-grade maraging steel allows the production of parts with a high hardness, which improves the service life and wear resistance of tooling or mould insert produced from this material. The material typically consists of a martensitic matrix material, with retained austenite and nano-precipitation. The transformatio...
Article
Full-text available
Laser-based powder bed fusion, due to its layer-by-layer nature, results in a unique stress profile in a part after the primary production process. The residual stresses are typically tensile near the top, while they are compressive near the bottom of the part. When it is removed without proper precautions, the part will bend excessively. In order...
Article
Full-text available
Residual stresses and deflections are two major issues in laser-based powder bed fusion (L-PBF) parts. One of the most efficient and reliable ways for predicting residual stresses and final distortions is via a calibrated numerical model. In this work, a part-scale finite element thermo-mechanical model for Ti6Al4V is developed in the commercial so...
Article
Full-text available
Due to its nature as a layer-by-layer production technique, the stresses and subsequent deformation from laser-based powder bed fusion are different from the ones observed in other manufacturing techniques. Additionally, because of the cyclic heating and cooling, the material undergoes significant microstructural changes during the process. Especia...
Article
Full-text available
Due to the layer-by-layer nature of the process, parts produced by laser-based powder bed fusion (LPBF) have high residual stresses, causing excessive deformations. To avoid this, parts are often post-processed by subjecting them to specially designed heat treatment cycles before or after their removal from the base plate. In order to investigate t...
Article
Full-text available
A heat treatment is an essential part of the metal additive manufacturing process chain. If an additively manufactured part, made of Ti-6Al-4 V, is heated above its β transus temperature, the columnar prior-β grains will become equiaxed β grains. This work quantitatively models this transition and the subsequent cooling down to room temperature by...
Preprint
Full-text available
In this paper, a multi-physics numerical model for multi-track-multi-layer laser powder bed fusion (L-PBF) process is developed and used for analysing the formation and evolution of porosities caused by lack of fusion and improper melting. The simulations are divided into two categories: first and foremost, a multi-physics thermo-fluid model in mes...
Conference Paper
Full-text available
PAM^2, which stands for Precision Additive Metal Manufacturing, is a European MSCA project in which 10 beneficiaries and 2 partners collaborate on improving the precision of metal Additive Manufacturing. Within this project, research is done for each process stage of AM, going from the design stage to modelling, fabricating, measuring and assessmen...
Conference Paper
Full-text available
The microstructure of parts produced by sective laser melting of Ti-6Al-4V is typically martensite in elongated prior  grains, which leads to anisotropic mechanical properties. A heat treatment can reduce this anisotropy by making these grains more equiaxed. In this work, simulations are performed wherein the evolution of the microstructure during...
Article
Full-text available
The entire process chain of selective laser melting of Ti-6Al-4V is analysed. First, a thermo-fluid dynamical model is used to investigate the temperature profile during the process and estimate the size and shape of the melt pool. The inclusion of the Marangoni effect improves upon previous work by showing the liquid velocity in the melt pool. Nex...

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Projects

Project (1)
Project
The overall objective of PAM^2 is to ensure the availability of high precision Additive Manufacturing processes and (computational) design procedures. Detailed objectives to reach this overall goal are: 1. to develop advanced (computational) design tools, enabling competitive designs, better use of AM possibilities against minimal design costs and reduced time-to-market 2. to develop better modelling tools for first-time-right processing 3. to optimise selective laser melting process strategies for improved part precision and feature accuracy 4. to understand the link between post-process metrology and in process observations, creating the basis for in-process quality control and process stability 5. to develop innovative in-process and post-process techniques to reduce or remove roughness, porosity and internal stresses and to improve dimensional accuracy and mechanical properties See also: https://www.pam2.eu