Connecting part geometry and cost for metal powder bed fusion

Budinoff, Hannah D.; Shafae, Mohammed

doi:10.1007/s00170-022-09688-x

Cited by 6 publications

(2 citation statements)

References 31 publications

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“…This can be confirmed by a validation experiment, where the powder packing density is measured from the real powder bed and compared to the packing density of the simulated powder bed, these validation methods are referred to as "PD-based validation" in this study. Such validation experiments have been developed across many studies conducted by various authors [11,13,22,23,25]. In [21] the "staircase" method, which was developed in [22], was used to validate a DEM recoating simulation.…”

Section: Figurementioning

confidence: 99%

“…particle size distribution or PSD [4] and particle morphology [5]), processing parameters (e.g., laser power [6], scanning speed [6], and layer thickness [7]), and post-process heat treatments [8] are carefully optimized. This is often done by practical experiments, by comparing the mechanical properties of finished parts resulting from each IOP Publishing doi:10.1088/1757-899X/1296/1/012020 2 combination of powder material or process parameters, which is labor-intensive, time consuming, and expensive, [9][10][11]. For this reason, it is an attractive proposition to replace experiments with computer simulation of the powder bed and the laser-material interaction.…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Validation of powder layering simulation via packing density measurement for laser-based powder bed fusion

Haapa,

Gopaluni,

Piili

et al. 2023

IOP Conf. Ser.: Mater. Sci. Eng.

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Powder bed fusion using a laser beam (PBF-LB/M) is considered one of the most versatile additive manufacturing methods as the parts printed have high resolution thanks to the low layer thickness used. The powder packing density (PD) of the powder layer has a significant impact on the density, surface roughness and other mechanical properties of the built parts. Due to the difficulty of characterizing the powder bed in situ, simulation has often been used to study the powder behavior on the powder bed. However, in order for the simulation to have practical value, there must be some way of confirming the results via experimental methods, also called validation. The aim of this study was to develop a powder packing density-based validation method for a powder bed simulation. The developed method featured a simplistic “open cup” style sample which traps powder inside for PD measurement. The samples were built with an EOS M 290 PBF-LB/M system using Alloy 718 (also known as “IN718” or “Inconel”) powder. Average PD over the five built samples was 52.4 %, with a standard deviation of 0.2 %. The method was used to successfully validate a powder bed simulation with four recoated powder layers, modelled using FLOW-3D DEM simulation software from Flow Science Inc. Similar methods for PD characterization were found in literature, but in many cases the method does not fully correspond to the conditions of a simulated powder bed, the scale is very small, or the reliability of the PD measurement is not confirmed. The method presented in this study corresponds to typical powder bed simulation conditions, while retaining high reliability and repeatability of results.

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