Development of an Empirical Model on Melt Pool Variation in Laser Foil Printing Additive Manufacturing Process Using Statistical Analysis

Sehhat, M. Hossein; Behdani, Behrouz; Hung, Chia-Hung; Mahdianikhotbesara, Ali

doi:10.1007/s13632-021-00795-x

Cited by 16 publications

(10 citation statements)

References 24 publications

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“…True adjustment of these process parameters requires the comprehensive understanding of the relationship among part’s characteristics and process parameters (Hung et al , 2020). Such a relationship between melt pool depths and process parameters were developed by Sehhat et al through performing thorough statistical analysis on the metallography results of melt pool depths created by various levels of process parameters (Sehhat et al , 2021b). The interaction between scan speed and laser power had a significant effect on melt pool depth, where it monotonically decreased by increasing the scan speed while it first increased and then decreased by increasing the laser power.…”

Section: Introductionmentioning

confidence: 99%

Development and experimental study of an automated laser-foil-printing additive manufacturing system

Hung

Turk

Sehhat

et al. 2022

RPJ

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Purpose This paper aims to present the development and experimental study of a fully automated system using a novel laser additive manufacturing technology called laser foil printing (LFP), to fabricate metal parts layer by layer. The mechanical properties of parts fabricated with this novel system are compared with those of comparable methodologies to emphasize the suitability of this process. Design/methodology/approach Test specimens and parts with different geometries were fabricated from 304L stainless steel foil using an automated LFP system. The dimensions of the fabricated parts were measured, and the mechanical properties of the test specimens were characterized in terms of mechanical strength and elongation. Findings The properties of parts fabricated with the automated LFP system were compared with those of parts fabricated with the powder bed fusion additive manufacturing methods. The mechanical strength is higher than those of parts fabricated by the laser powder bed fusion and directed energy deposition technologies. Originality/value To the best knowledge of authors, this is the first time a fully automated LFP system has been developed and the properties of its fabricated parts were compared with other additive manufacturing methods for evaluation.

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Section: Introductionmentioning

confidence: 99%

Development and experimental study of an automated laser-foil-printing additive manufacturing system

Hung

Turk

Sehhat

et al. 2022

RPJ

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“…Additive Manufacturing (AM) has improved the traditional method of part production through the elimination of several inner-process manufacturing steps, and post-processing like heat treatment [1][2][3][4]. The layer-by-layer production fashion of AM can fabricate parts with complicated geometries in a single-step process [5][6][7][8][9][10]. Researchers have extensively investigated the AM from different viewpoints in the past decade.…”

Section: Introductionmentioning

confidence: 99%

Verification of stress transformation in anisotropic material additively manufactured by fused deposition modeling (FDM)

Sehhat

Mahdianikhotbesara

Yadegari

2022

Int J Adv Manuf Technol

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The widespread use of Additive Manufacturing (AM) has been extensively progressed in the past decade due to the convenience provided by AM in rapid and reliable part production. Fused Deposition Modeling (FDM) has witnessed even faster growth of application as its equipment is environmentally-friendly and easily adaptable. This increased use of FDM to manufacture prototypes and nished parts is accompanied by concerns that 3D printed parts do not perform the same as relatively homogeneous parts produced by molding or machining. As the interface between two faces of bonded material may be modeled by stress elements, in theory by modeling 3D printed layers subjected to tension at varying angles as transformed stress elements, the stress required to break the layer bonds can be determined. To evaluate such a relationship, in this study, the stresses calculated from stress transformation were compared with the behavior of 3D printed specimens subjected to tensile loads. The maximum principal stress was found to be constant relative to the layer angle, regardless of whether the specimen experienced failure at the layer interface or within the layer material, although the specimens with layers 75° relative to the load were notable exceptions to this nding. This failure at much lower stresses for the samples used in the 75° tests may be attributed to a possible environmental factor, such as temperature or humidity change, degrading the samples' structural integrity.

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“…In composite 3D printing, fiber impregnation by the melted matrix is controlled by matrix viscosity and print speed and plays a crucial role in the mechanical properties of printed composites. In the LFP method, the melt pool depths as a function of laser power and scan speed determine the properties of LFP fabricated parts (Sehhat et al , 2021). It should be noted that continuous fiber 3D printing has complexities and considerations in terms of preparation of raw materials, printing conditions, 3D printer hardware and slicer software.…”

Section: Introductionmentioning

confidence: 99%

An experimental and numerical investigation on mechanical properties of 3D printed continuous glass tow preg-reinforced composites

Mosleh

Dariushi

Esfandeh

2022

RPJ

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Purpose In this paper, continuous glass tow preg-reinforced acrylonitrile butadiene styrene (ABS) composites were fabricated by using a 3D printing method, and the purpose of this study is the investigation of the fiber preimpregnation effect on the mechanical behavior of these composites. In addition, a simple theoretical approach (mixture law), which considers the elastic behavior of reinforced composites and a numerical simulation method based on finite element method (FEM), was used to predict the tensile stress–strain behavior of ABS/glass tow preg composites in the elastic region. Design/methodology/approach Different groups of preimpregnated glass tows with various ABS amounts (named 2%, 10%, 20% and 30%) were prepared by the solution impregnation method. Then, preimpregnated glass tows (prepregs or tow-pregs) were fed into the printer head along with the polymeric ABS filament to print the composites. The tensile, flexural and short beam tests were conducted to evaluate the mechanical properties of the printed composites. Findings The first result of using tow-pregs instead of dry tows in continuous fiber 3D printing is much easier printing, printability improvement and the possibility of printing layers with low thickness, which can further increase the mechanical properties. The mechanical test results showed all of the glass prepregs improve strength and modulus in the tensile, three-point bending and short beam tests compared with neat ABS specimens, but statistical analysis showed that ABS weight percentage in the prepregs had no significant effect on the mechanical strength of composites except for the tensile modulus. Samples containing 2%-prepreg (minimum ABS amount in the tow-pregs) showed a significant improvement in tensile modulus. In the simulation section, good agreement is obtained between the model predictions and experimental tensile results. The results show that an acceptable deviation (14%) exists between the experimental and predicted value of elastic modulus by the numerical model. Originality/value To the best of the authors’ knowledge, this is the first study showing the effects of ABS weight percentage in prepregs on the mechanical properties of 3D printed continuous fiber-reinforced composites and predicting the mechanical behavior of 3D printed composites by numerical simulation method.

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Development of an Empirical Model on Melt Pool Variation in Laser Foil Printing Additive Manufacturing Process Using Statistical Analysis

Cited by 16 publications

References 24 publications

Development and experimental study of an automated laser-foil-printing additive manufacturing system

Development and experimental study of an automated laser-foil-printing additive manufacturing system

Verification of stress transformation in anisotropic material additively manufactured by fused deposition modeling (FDM)

An experimental and numerical investigation on mechanical properties of 3D printed continuous glass tow preg-reinforced composites

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