Build position-based dimensional deviations of laser powder-bed fusion of stainless steel 316L

Veetil, Jithin Kozhuthala; Khorasani, Mahyar; Ghasemi, Arman; Rolfe, Bernard; Vrooijink, Ivo; Beurden, Karin Van; Moes, Sebastiaan; Gibson, Ian

doi:10.1016/j.precisioneng.2020.09.024

Cited by 17 publications

(8 citation statements)

References 13 publications

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“…In LB-PBF, the position of the samples also influences the dimensional accuracy. It is reported (Veetil et al , 2021) that because of the cooling effect of the window in the build chamber and the flow of the inert gas, different dimensional deviations were obtained for most of the LB-PBF metal components.…”

Section: Characteristics Of Produced Componentsmentioning

confidence: 99%

Laser subtractive and laser powder bed fusion of metals: review of process and production features

Khorasani¹,

Gibson

Ghasemi³

et al. 2023

RPJ

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Purpose The purpose of this study is, to compare laser-based additive manufacturing and subtractive methods. Laser-based manufacturing is a widely used, noncontact, advanced manufacturing technique, which can be applied to a very wide range of materials, with particular emphasis on metals. In this paper, the governing principles of both laser-based subtractive of metals (LB-SM) and laser-based powder bed fusion (LB-PBF) of metallic materials are discussed and evaluated in terms of performance and capabilities. Using the principles of both laser-based methods, some new potential hybrid additive manufacturing options are discussed. Design methodology approach Production characteristics, such as surface quality, dimensional accuracy, material range, mechanical properties and applications, are reviewed and discussed. The process parameters for both LB-PBF and LB-SM were identified, and different factors that caused defects in both processes are explored. Advantages, disadvantages and limitations are explained and analyzed to shed light on the process selection for both additive and subtractive processes. Findings The performance of subtractive and additive processes is highly related to the material properties, such as diffusivity, reflectivity, thermal conductivity as well as laser parameters. LB-PBF has more influential factors affecting the quality of produced parts and is a more complex process. Both LB-SM and LB-PBF are flexible manufacturing methods that can be applied to a wide range of materials; however, they both suffer from low energy efficiency and production rate. These may be useful when producing highly innovative parts detailed, hollow products, such as medical implants. Originality value This paper reviews the literature for both LB-PBF and LB-SM; nevertheless, the main contributions of this paper are twofold. To the best of the authors’ knowledge, this paper is one of the first to discuss the effect of the production process (both additive and subtractive) on the quality of the produced components. Also, some options for the hybrid capability of both LB-PBF and LB-SM are suggested to produce complex components with the desired macro- and microscale features.

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Section: Characteristics Of Produced Componentsmentioning

confidence: 99%

Laser subtractive and laser powder bed fusion of metals: review of process and production features

Khorasani¹,

Gibson

Ghasemi³

et al. 2023

RPJ

Self Cite

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“…MC is a marketing and manufacturing approach that supports the personalisation of products. It revolves around the needs of the customer, and in AM is based on innovations in technology since the 1970s (Gibson et al , 2021e, Veetil et al , 2021; Khorasani et al , 2019c). Performing MC in conventional manufacturing is difficult because of both the geometrical limitations of established manufacturing techniques and the high cost of tooling.…”

Section: Exclusive Features Of Additive Manufacturing To Enhance Indu...mentioning

confidence: 99%

A review of Industry 4.0 and additive manufacturing synergy

Khorasani¹,

Loy

Ghasemi

et al. 2022

RPJ

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Purpose This paper reviews the synergy of Industry 4.0 and additive manufacturing (AM) and discusses the integration of data-driven manufacturing systems and product service systems as a key component of the Industry 4.0 revolution. This paper aims to highlight the potential effects of Industry 4.0 on AM via tools such as digitalisation, data transfer, tagging technology, information in Industry 4.0 and intelligent features. Design/methodology/approach In successive phases of industrialisation, there has been a rise in the use of, and dependence on, data in manufacturing. In this review of Industry 4.0 and AM, the five pillars of success that could see the Internet of Things (IoT), artificial intelligence, robotics and materials science enabling new levels of interactivity and interdependence between suppliers, producers and users are discussed. The unique effects of AM capabilities, in particular mass customisation and light-weighting, combined with the integration of data and IoT in Industry 4.0, are studied for their potential to support higher efficiencies, greater utility and more ecologically friendly production. This research also illustrates how the digitalisation of manufacturing for Industry 4.0, through the use of IoT and AM, enables new business models and production practices. Findings The discussion illustrates the potential of combining IoT and AM to provide an escape from the constraints and limitations of conventional mass production whilst achieving economic and ecological savings. It should also be noted that this extends to the agile design and fabrication of increasingly complex parts enabled by simulations of complex production processes and operating systems. This paper also discusses the relationship between Industry 4.0 and AM with respect to improving the quality and robustness of product outcomes, based on real-time data/feedback. Originality/value This research shows how a combined approach to research into IoT and AM can create a step change in practice that alters the production and supply paradigm, potentially reducing the ecological impact of industrial systems and product life cycle. This paper demonstrates how the integration of Industry 4.0 and AM could reshape the future of manufacturing and discusses the challenges involved.

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“…A significant improvement in the tensile strength can be obtained with grain refinement processes rather than heat treatment. The build orientation and location in the build plate also affect the strength of the component, as the fracture behavior is different when horizontal vs. vertical [18,19]. Casati et al [20] plotted the stress-strain behavior of tensile specimens built vertically and horizontally with 580 MPa and 684 MPa of UTS.…”

Section: Tensile Strengthmentioning

confidence: 99%

A Critical Review on Effect of Process Parameters on Mechanical and Microstructural Properties of Powder-Bed Fusion Additive Manufacturing of SS316L

et al. 2021

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Additive manufacturing (AM) is one of the recently studied research areas, due to its ability to eliminate different subtractive manufacturing limitations, such as difficultly in fabricating complex parts, material wastage, and numbers of sequential operations. Laser-powder bed fusion (L-PBF) AM for SS316L is known for complex part production due to layer-by-layer deposition and is extensively used in the aerospace, automobile, and medical sectors. The process parameter selection is crucial for deciding the overall quality of the SS316L build component with L-PBF AM. This review critically elaborates the effect of various input parameters, i.e., laser power, scanning speed, hatch spacing, and layer thickness, on various mechanical properties of AM SS316L, such as tensile strength, hardness, and the effect of porosity, along with the microstructure evolution. The effect of other AM parameters, such as the build orientation, pre-heating temperature, and particle size, on the build properties is also discussed. The scope of this review also concerns the challenges in practical applications of AM SS316L. Hence, the residual stress formation, their influence on the mechanical properties and corrosion behavior of the AM build part for bio implant application is also considered. This review involves a detailed comparison of properties achievable with different AM techniques and various post-processing techniques, such as heat treatment and grain refinement effects on properties. This review would help in selecting suitable process parameters for various human body implants and many different applications. This study would also help to better understand the effect of each process parameter of PBF-AM on the SS316L build part quality.

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Build position-based dimensional deviations of laser powder-bed fusion of stainless steel 316L

Cited by 17 publications

References 13 publications

Laser subtractive and laser powder bed fusion of metals: review of process and production features

Laser subtractive and laser powder bed fusion of metals: review of process and production features

A review of Industry 4.0 and additive manufacturing synergy

A Critical Review on Effect of Process Parameters on Mechanical and Microstructural Properties of Powder-Bed Fusion Additive Manufacturing of SS316L

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