Absorbance study of powder conditions for laser additive manufacturing

Brandau, Benedikt; Silva, Adrien Da; Brueckner, Frank; Kaplan, Alexander

doi:10.1016/j.matdes.2022.110591

Cited by 42 publications

(7 citation statements)

References 49 publications

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“…The minimal absorption increase for the P1 powder sample can be connected to multiple reflections. According to [ 38 ], it can appear when the beam is reflected away by the powder bed more than one time. Authors of [ 38 ] mention that the reason for multiple reflections is the grain size and shape.…”

Section: Discussionmentioning

confidence: 99%

“…According to [ 38 ], it can appear when the beam is reflected away by the powder bed more than one time. Authors of [ 38 ] mention that the reason for multiple reflections is the grain size and shape. Both the particles smaller than the beam’s diameter and non-spherical particles can cause the multiple reflections and therefore increased the absorption.…”

Section: Discussionmentioning

confidence: 99%

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Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

et al. 2022

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Additive manufacturing (AM) is dynamically developing and finding applications in different industries. The quality of input material is a part of the process and of the final product quality. That is why understanding the influence of powder reuse on the properties of bulk specimens is crucial for ensuring the repeatable AM process chain. The presented study investigated the possibility of continuous reuse of AlSi7Mg0.6 powder in the laser powder bed fusion process (LPBF). To date, there is no study of AlSi7Mg0.6 powder reuse in the LPBF process to be found in the literature. This study aims to respond to this gap. The five batches of AlSi7Mg0.6 powder and five bulk LPBF samples series were characterised using different techniques. The following characteristics of powders were analysed: the powder size distribution (PSD), the morphology (scanning electron microscopy—SEM), the flowability (rotating drum analysis), and laser light absorption (spectrophotometry). Bulk samples were characterised for microstructure (SEM), chemical composition (X-ray fluorescence spectrometry—XRF), porosity (computed tomography—CT) and mechanical properties (tensile, hardness). The powder was reused in subsequent processes without adding (recycling/rejuvenation) virgin powder (collective ageing powder reuse strategy). All tested powders (powders P0–P4) and bulk samples (series S0–S3) show repeatable properties, with changes observed within error limits. Samples manufactured within the fifth reuse cycle (series S4) showed some mean value changes of measured characteristics indicating initial degradation. However, these changes also mostly fit within error limits. Therefore, the collective ageing powder reuse strategy is considered to give repeatable LPBF process results and is recommended for the AlSi7Mg0.6 alloy within at least five consecutive LPBF processes.

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Section: Discussionmentioning

confidence: 99%

Section: Discussionmentioning

confidence: 99%

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

et al. 2022

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“…Their research showed that ultraviolet radiation emitted into high-concentration suspension would produce both light scattering and absorption phenomena, and the square of the refractive index difference between particles and medium controlled the curing depth. It should be emphasized that their research object is ceramics powder with low UV absorbance, while it has been proved that the absorption of pure copper to UV light at 385 nm wavelength is more than 90% [ 28 ]. Photocurable printing is a process in which a photosensitive resin absorbs UV light and causes curing.…”

Section: Methodsmentioning

confidence: 99%

Precision Control in Vat Photopolymerization Based on Pure Copper Paste: Process Parameters and Optimization Strategies

et al. 2023

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Vat photopolymerization (VPP) presents new opportunities for metals to achieve the design freedom of components. However, the material properties of copper powder and the inherent defects of the technology seriously hinder its application in high-precision metal additive manufacturing. Precision control is the key to obtaining minimal precision metal parts when copper is prepared by reduction photopolymerization. This paper employed variance analysis (ANOVA) and root mean square deviation (RMSD) to determine the significant parameters affecting dimensional accuracy and their optimal regions. The results show that printing accuracy is improved by optimizing exposure time, intensity, layer thickness, and sweeper moving speed. When the exposure time is 21 s, and the exposure intensity is 220 mW/cm2, a hole with a height of 1 mm and a diameter of 200 μm can be printed with a minimum size deviation of 51 μm. In addition, RMSD and ANOVA provide an effective method for realizing high-precision stereolithography 3D printing metal copper, expanding the material adaptation in the 3D printing metals field. The study highlights the potential of VPP as a method for preparing metals in future studies.

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“…[ 16 ] However, metallic materials typically exhibit high reflectance to light ranging from visible to near infrared wavelengths, resulting in low energy utilization rate and limited heating temperature during the laser sintering process. [ 17 ] This presents a significant challenge in meeting the sintering requirements for refractory metals. Moreover, increased laser radiation may lead to severe oxidation and overablation rather than better sintering results.…”

Section: Introductionmentioning

confidence: 99%

Printing Three‐Dimensional Refractory Metal Patterns in Ambient Air: Toward High Temperature Sensors

Wang

et al. 2023

Advanced Science

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Refractory metals offer exceptional benefits for high temperature electronics including high‐temperature resistance, corrosion resistance and excellent mechanical strength, while their high melting temperature and poor processibility poses challenges to manufacturing. Here this work reports a direct ink writing and tar‐mediated laser sintering (DIW‐TMLS) technique to fabricate three‐dimensional (3D) refractory metal devices for high temperature applications. Metallic inks with high viscosity and enhanced light absorbance are designed by utilizing coal tar as binder. The printed patterns are sintered into oxidation‐free porous metallic structures using a low‐power (<10 W) laser in ambient environment, and 3D freestanding architectures can be rapidly fabricated by one step. Several applications are presented, including a fractal pattern‐based strain gauge, an electrically small antenna (ESA) patterned on a hemisphere, and a wireless temperature sensor that can work up to 350 °C and withstand burning flames. The DIW‐TMLS technique paves a viable route for rapid patterning of various metal materials with wide applicability, high flexibility, and 3D conformability, expanding the possibilities of harsh environment sensors.

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Absorbance study of powder conditions for laser additive manufacturing

Cited by 42 publications

References 49 publications

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

Precision Control in Vat Photopolymerization Based on Pure Copper Paste: Process Parameters and Optimization Strategies

Printing Three‐Dimensional Refractory Metal Patterns in Ambient Air: Toward High Temperature Sensors

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