Analysis of the machinability when milling AlSi10Mg additively manufactured via laser-based powder bed fusion

Zimmermann, Marco; Müller, Dominik; Kirsch, Benjamin; Greco, Sebastian; Aurich, Jan C.

doi:10.1007/s00170-020-06391-7

Cited by 29 publications

(8 citation statements)

References 51 publications

(71 reference statements)

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“…The rapidly growing additive manufacturing (AM) processing has simplified the fabrication of complex and customized shapes with different metals [1][2][3][4]. The standard AM route involves layer-by-layer consolidation of a metal powder using different energy sources such as laser or electron beam [5][6][7].…”

Section: Introductionmentioning

confidence: 99%

Copper additive manufacturing using MIM feedstock: adjustment of printing, debinding, and sintering parameters for processing dense and defectless parts

Singh

Missiaen

Bouvard

et al. 2021

Int J Adv Manuf Technol

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In the present study, an additive manufacturing process of copper using extrusion 3D printing, solvent and thermal debinding, and sintering was explored. Extrusion 3D printing of metal injection moulding (MIM) feedstock was used to fabricate green body samples. The printing process was performed with optimized parameters to achieve high green density and low surface roughness. To remove water-soluble polymer, the green body was immersed in water for solvent debinding. The interconnected voids formed during solvent debinding were favorable for removing the backbone polymer from the brown body during thermal debinding. Thermal debinding was performed up to 500 °C, and ~ 6.5% total weight loss of the green sample was estimated. Finally, sintering of the thermally debinded samples was performed at 950, 1000, 1030, and 1050°C. The highest sintering temperature provided the highest relative density (94.5%) and isotropic shrinkage. Micro-computed tomography (μCT) examination was performed on green samples and sintered samples, and qualitative and quantitative analysis of the porosity confirmed the benefits of optimized printing conditions for the final microstructure. This work opens up the opportunity for 3D printing and sintering to produce pure copper components with complicated shapes and high density, utilizing raw MIM feedstock as the starting material.

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Section: Introductionmentioning

confidence: 99%

Copper additive manufacturing using MIM feedstock: adjustment of printing, debinding, and sintering parameters for processing dense and defectless parts

Singh

Missiaen

Bouvard

et al. 2021

Int J Adv Manuf Technol

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“…The problem was the appearance of burrs and chipping that adhered to the treated surface, reducing its quality. Zimmermann et al [13], who conducted research on milling using analogous samples, came to very similar conclusions.…”

Section: Introductionmentioning

confidence: 80%

“…Obviously, the capabilities of AM technology are somewhat limited. In practice, additional machining operations are often used to improve the dimensional and shape accuracy or better finish the surface of the product [13]. In the case of aluminum alloys, with some exceptions (e.g.…”

Section: Introductionmentioning

confidence: 99%

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Study on Chip Breakability Index During Longitudinal Turning of Cast and DMLS Additively Manufactured AlSi10Mg Aluminum Alloy

Struzikiewicz¹,

Słodki²,

Zębala³

et al. 2022

Adv. Sci. Technol. Res. J.

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The article presents selected issues related to the process of turning samples made of the AlSi10Mg alloy with the use of various manufacturing technologies, i.e. casting and DMLS (Direct Metal Laser Sintering). Machining processes of cylindrical surfaces of samples made with these two methods were subjected to a comparative analysis. The main idea behind the research was to develop guidelines for turning parts obtained using laser powder sintering. Study on the infl uence of cutting parameters on the value of breakability index C in . as well as the type, shape and form of chips produced during longitudinal turning is presented. The chips were also measured and the results of the microscopic analysis of the chips form are described. Results showed that the values of C in index for turning of the cast AlSi10MG alloy depend mainly on the value of feed f. According to adopted chip classifi cation for the feed value of f > 0.1 mm/rev the chips had a favorable, short form. In the case of turning the sample obtained by the DMLS method, the values of the chip breakability index C in are not signifi cantly dependent on the adopted ranges of cutting parameters. The Taguchi method was used to develop the conclusions obtained on the basis of the research results.

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“…19 Zimmermann et al have analysed the dependence of laser powder bed fusion (LPBF) manufacturing parameters on the chip and surface morphology as well as burr formation and milling forces of the AlSi10Mg. 20 The results are compared with conventional (cast) AlSi10Mg and suggest that LPBF influences its machinability. The authors claim that metallurgical condition of the part needs to be considered when submitted to finishing operations, in order to achieve suitable results.…”

Section: Introductionmentioning

confidence: 99%

Comparison of the machinability of the 316L and 18Ni300 additively manufactured steels based on turning tests

Silva

Amaral

Couto

et al. 2021

Proceedings of the Institution of Mechanical Engineers, Part L:

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This paper focuses on the machinability of additively manufactured steel alloys (316L stainless steel and 18Ni300 Maraging steel) by reference to their conventional metallurgical conditions. The machinability of both metallurgical conditions has been evaluated by longitudinal turning tests under laboratory conditions using two different cutting tool geometries (flat rake face and chip-breaker geometry) and covering different cutting speeds, depths of cut and feed values. Cutting forces, chip morphology and surface roughness were investigated as machinability indicators. The influence of chip-breaker on process performance was also analysed. For a comprehensive discussion of the results, microstructure, chemical composition, surface roughness and mechanical strength of both metallurgical conditions were studied. The paper quantitatively demonstrates that despite the higher mechanical strength of additively manufactured alloys, no significant power requirements were verified for the finishing cutting of tested alloys, when compared with conventional materials. Also noteworthy, is the surface quality improvement of the printed samples due to the most favourable conditions for chip formation. The usage of a chip breaker insert had higher impact on reducing required cutting energy than on controlling chip geometry.

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Analysis of the machinability when milling AlSi10Mg additively manufactured via laser-based powder bed fusion

Cited by 29 publications

References 51 publications

Copper additive manufacturing using MIM feedstock: adjustment of printing, debinding, and sintering parameters for processing dense and defectless parts

Copper additive manufacturing using MIM feedstock: adjustment of printing, debinding, and sintering parameters for processing dense and defectless parts

Study on Chip Breakability Index During Longitudinal Turning of Cast and DMLS Additively Manufactured AlSi10Mg Aluminum Alloy

Comparison of the machinability of the 316L and 18Ni300 additively manufactured steels based on turning tests

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