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A three-dimensional fully auxetic cellular structure with negative Poisson’s ratio is presented. Samples are fabricated from Ti6Al4V powder via selective electron beam melting. The influence of the strut thickness and the amplitude of the strut on the mechanical properties and the deformation behaviour of cellular structures is studied.

Purpose The purpose of this study is the introduction and validation of a new technique for process monitoring during electron beam melting (EBM). Design/methodology/approach In this study, a backscatter electron detector inside the building chamber is used for image acquisition during EBM process. By systematic variation of process parameters, the ability of displaying different topographies, especially pores, is investigated. The results are evaluated in terms of porosity and compared with optical microscopy and X-ray computed tomography. Findings The method is capable of detecting major flaws (e.g. pores) and gives information about the quality of the resulting component. Originality/value Image acquisition by evaluating backscatter electrons during EBM process is a new approach in process monitoring which avoids disadvantages restricting previously investigated techniques.

Abstract:In order to understand the absorption characteristic, a ray trace model is developed by taking into account the reflection, absorption and refraction. The ray paths are resolved on a sub-powder grid. For validation, the simulation results are compared to analytic solutions of the irradiation of the laser beam onto a plain surface. In addition, the absorptance, reflectance and transmittance of PA12 powder layers measured by an integration sphere setup are compared with the numerical results of our model. It is shown that the effective penetration depth can be lower than the penetration depth in bulk material for polymer powders and, therefore, can increase the energy density at the powder bed surface. The implications for modeling of the selective laser sintering (SLS) process and the processability of fine powder distributions and high powder bed densities are discussed.

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