Additive Manufacturing: Reproducibility of Metallic Parts

Prashanth, Konda Gokuldoss; Scudino, Sergio; Chatterjee, Riddhi P.; Salman, O.O.; Eckert, Jürgen

doi:10.3390/technologies5010008

Cited by 46 publications

(23 citation statements)

References 24 publications

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“…In conclusion, while the ability to manufacture SLM samples with reproducible properties (e.g. tensile strength), keeping the same process parameters and powder quality, has been proven [46], we point out new important aspects that need full consideration while producing components or test specimens in series. Factors such as the position inside the build chamber or the homogeneity of gas flow need to be investigated in a more systematic manner, and possibly other parameters in the build job need also to be taken into account.…”

Section: Discussionmentioning

confidence: 95%

New aspects about the search for the most relevant parameters optimizing SLM materials

Mishurova

Artzt

Haubrich

et al. 2019

Additive Manufacturing

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While the volumetric energy density is commonly used to qualify a process parameter set, and to quantify its influence on the microstructure and performance of additively manufactured (AM) materials and components, it has been already shown that this description is by no means exhaustive. In this work, new aspects of the optimization of the selective laser melting process are investigated for AM Ti-6Al-4V. We focus on the amount of near-surface residual stress (RS), often blamed for the failure of components, and on the porosity characteristics (amount and spatial distribution). First, using synchrotron x-ray diffraction we show that higher RS in the subsurface region is generated if a lower energy density is used. However, we show that laser de-focusing and sample positioning inside the build chamber also play an eminent role, and we quantify this influence. In parallel, using X-ray Computed Tomography, we observe that porosity is mainly concentrated in the contour region, except in the case where the laser speed is small. The low values of porosity (less than 1%) do not influence RS.

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Section: Discussionmentioning

confidence: 95%

New aspects about the search for the most relevant parameters optimizing SLM materials

Mishurova

Artzt

Haubrich

et al. 2019

Additive Manufacturing

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“…The tensile tests were carried out in the as-prepared condition without any external heat treatment. The samples were all built in one and the same build spread across the substrate plate [20][21][22].…”

Section: Methodsmentioning

confidence: 99%

Is the energy density a reliable parameter for materials synthesis by selective laser melting?

Prashanth

Scudino

Maity

et al. 2017

Materials Research Letters

326

104

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The effective fabrication of materials using selective laser melting depends on the process parameters. Here, we analyse the suitability of the energy density to represent the energy transferred to the powder bed, which is effectively used to melt the particles and to produce the bulk specimens. By properly varying laser power and speed in order to process the powder at constant energy density, we show that the equation currently used to calculate the energy density gives only an approximate estimation and that hatch parameters and material properties should be considered to correctly evaluate the energy density. IMPACT STATEMENTAl-12Si SLM samples were fabricated at constant energy density. The laser power and laser scan speed combination variation was used to demonstrate the significant changes needed with energy density equation. ARTICLE HISTORY

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“…Conventional manufacturing involves molding, machining, joining, forming and finishing of a bulk material resulting in a high material input, huge material wastage and excessive labour cost . Alternatively, AM is a rapid prototyping technology where 3D components are built by adding layer‐upon‐layer of material with sequential melting, on the basis of a computer‐generated model . AM has already made a profound impact in the aerospace, medical and automobile industries, rapidly foraying into electronics, energy, aesthetics, sports and construction sectors .…”

Section: Introductionmentioning

confidence: 97%

Competition between densification and microstructure of functionalmaterials by Selective Laser Melting

Singh

Ummethala

Hameed³

et al. 2020

Mat Design & Process Comms

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Functional materials like bulk metallic glasses (BMGs) and magnetocaloric materials (MCMs) are multi‐component alloys, possessing a unique combination of structural and functional properties. However, the complexity involved in manufacturing these materials limits their fabrication to rather simple shapes that are incapable of achieving full functionality. Laser‐based powder bed fusion (LPBF) or Selective Laser Melting (SLM) is an additive manufacturing (AM) technique that enables the fabrication of BMGs and MCGs in the form of complex shapes. However, high heating and cooling rates in SLM preclude complete amorphous phase formation (in BMGs) at higher energy densities that are essential for achieving a high relative density with minimal defects/pores. The optimization of process parameters and precursor powder characteristics have been the subject of intense research. The optimization is a must requirement to achieve the balance between high densification with no crystalline phase formation. The present review elaborates on the challenges concerning the SLM of BMGs and MCMs and addresses the current progress. The lack of sufficient studies on the SLM of MCMs presents several research opportunities. A summary of important outcomes and future prospects are discussed.

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Additive Manufacturing: Reproducibility of Metallic Parts

Cited by 46 publications

References 24 publications

New aspects about the search for the most relevant parameters optimizing SLM materials

New aspects about the search for the most relevant parameters optimizing SLM materials

Is the energy density a reliable parameter for materials synthesis by selective laser melting?

Competition between densification and microstructure of functionalmaterials by Selective Laser Melting

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