Development of powder bed fusion – laser beam process for AISI 4140, 4340 and 8620 low-alloy steel

Hearn, William; Harlin, Peter; Hryha, Eduard

doi:10.1080/00325899.2022.2134083

Cited by 5 publications

(2 citation statements)

References 33 publications

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“…In the context of manufacturing the low-alloyed Q&T steel 42CrMo4 via powder bed-based AM techniques, studies using the PBF-EB/M process are still limited; only two studies [ 1 , 14 ] can be found in the open literature. In contrast, several studies available have focused on PBF-LB/M-processed 42CrMo4 [ 15 , 16 , 17 , 18 ], revealing that the process is capable of producing parts of low porosity. However, the open literature draws attention to the challenges being related to the PBF-LB/M processing of carbon-containing steels, e.g., crack formation or high local stresses [ 15 ].…”

Section: Introductionmentioning

confidence: 99%

Pathways toward the Use of Non-Destructive Micromagnetic Analysis for Porosity Assessment and Process Parameter Optimization in Additive Manufacturing of 42CrMo4 (AISI 4140)

Engelhardt,

Wegener,

Niendorf

2024

Materials

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Laser-based powder bed fusion of metals (PBF-LB/M) is a widely applied additive manufacturing technique. Thus, PBF-LB/M represents a potential candidate for the processing of quenched and tempered (Q&T) steels such as 42CrMo4 (AISI 4140), as these steels are often considered as the material of choice for complex components, e.g., in the toolmaking industry. However, due to the presence of process-induced defects, achieving a high quality of the resulting parts remains challenging in PBF-LB/M. Therefore, an extensive quality inspection, e.g., using process monitoring systems or downstream by destructive or non-destructive testing (NDT) methods, is essential. Since conventionally used downstream methods, e.g., X-ray computed tomography, are time-consuming and cost-intensive, micromagnetic NDT measurements represent an alternative for ferromagnetic materials such as 42CrMo4. In this context, 42CrMo4 samples were manufactured by PBF-LB/M with different process parameters and analyzed using a widely established micromagnetic measurement system in order to investigate potential relations between micromagnetic properties and porosity. Using multiple regression modeling, relations between the PBF-LB/M process parameters and six selected micromagnetic variables and relations between the process parameters and the porosity were assessed. The results presented reveal first insights into the use of micromagnetic NDT measurements for porosity assessment and process parameter optimization in PBF-LB/M-processed components.

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Section: Introductionmentioning

confidence: 99%

Pathways toward the Use of Non-Destructive Micromagnetic Analysis for Porosity Assessment and Process Parameter Optimization in Additive Manufacturing of 42CrMo4 (AISI 4140)

Engelhardt,

Wegener,

Niendorf

2024

Materials

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“…The powder-bed-based additive manufacturing such as selective laser sintering (SLS) or selective laser melting (SLM) has a wide range of applications in the industry [1], which is an advanced technology that allows creative design and integrative manufacturing of complex parts to meet the growing needs of high-end industries [2]. In order to reduce the warpage and residual stress of AM parts, the powder spreading process in the SLS/SLM is usually performed at preheating temperature [3].…”

Section: Introductionmentioning

confidence: 99%

Powder flowability characterisation at preheating temperature in additive manufacturing

Zhang

Liu

2023

Powder Metallurgy

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The powder spreading process is usually performed at preheating temperature in powder-bedbased additive manufacturing (AM). Thus, the powder flowability characterisation at preheating temperature is important for powder spreading processes. However, devices for traditional powder flowability characterising methods are mainly designed for specific conditions at room temperature and cannot consider the effect of temperature on powder flowability. In this work, an experimental platform with a heated rotating drum was set up and a high-speed camera was used to record powder avalanche processes in a heated rotating drum for the powder flowability characterisation at preheating temperature. Nylon and stainless steel powder flowability at different temperatures was assessed by the statistical analysis of avalanche angle, avalanche time, arithmetic mean deviation and surface linearity of powder surface profile. Four parameters provide a good characterisation of powder flowability. The results can provide guidance for the powder flowability characterisation method at preheating temperature in AM.

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Additive manufacturing of ultra-high strength steels: A review

Yang

Gong

et al. 2023

Journal of Alloys and Compounds

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Development of powder bed fusion – laser beam process for AISI 4140, 4340 and 8620 low-alloy steel

Cited by 5 publications

References 33 publications

Pathways toward the Use of Non-Destructive Micromagnetic Analysis for Porosity Assessment and Process Parameter Optimization in Additive Manufacturing of 42CrMo4 (AISI 4140)

Pathways toward the Use of Non-Destructive Micromagnetic Analysis for Porosity Assessment and Process Parameter Optimization in Additive Manufacturing of 42CrMo4 (AISI 4140)

Powder flowability characterisation at preheating temperature in additive manufacturing

Additive manufacturing of ultra-high strength steels: A review

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