Effect of processing parameters on overhanging surface roughness during laser powder bed fusion of AlSi10Mg

Yang, Tiankui; Liu, Tingting; Liao, Wenhe; Wei, Huiliang; Zhang, Changdong; Chen, Xiangyuan; Zhang, Kai

doi:10.1016/j.jmapro.2020.11.030

Cited by 50 publications

(20 citation statements)

References 21 publications

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“… Plot of surface roughness as a function of the main categories of commercially available materials for PBF-LB/M production [ 130 , 131 , 132 , 133 , 134 , 135 , 136 , 137 , 138 , 139 , 140 , 141 , 142 , 143 , 144 , 145 , 146 , 147 , 148 , 149 , 150 , 151 , 152 , 153 , 154 , 155 , 156 , 157 , 158 , 159 , 160 , 161 , 162 , 163 ]. …”

Section: Figurementioning

confidence: 99%

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

2023

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Their high strength-to-weight ratio, good corrosion resistance and excellent thermal and electrical conductivity have exponentially increased the interest in aluminium alloys in the context of laser-based powder bed fusion (PBF-LB/M) production. Although Al-based alloys are the third most investigated category of alloys in the literature and the second most used in industry, their processing by PBF-LB/M is often hampered by their considerable solidification shrinkage, tendency to oxidation, high laser reflectivity and poor powder flowability. For these reasons, high-strength Al-based alloys traditionally processed by conventional procedures have often proved to be unprintable with additive technology, so the design and development of new tailored Al-based alloys for PBF-LB/M production is necessary. The aim of the present work is to explore all the challenges encountered before, during and after the PBF-LB/M processing of Al-based alloys, in order to critically analyse the solutions proposed in the literature and suggest new approaches for addressing unsolved problems. The analysis covers the critical aspects in the literature as well as industrial needs, industrial patents published to date and possible future developments in the additive market.

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Section: Figurementioning

confidence: 99%

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

2023

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“…Thus, the orientation angles on the part surface and the quality of the fabricated part must be evaluated to determine the suitable critical overhang angles for various fabrication conditions and applications. Yang et al [ 20 ] investigated the effect of orientation angle in LPBF, as it determines the surface quality of parts fabricated using AlSi10Mg metal powder.…”

Section: Algorithm For Supporting Effectmentioning

confidence: 99%

Facet Connectivity-Based Estimation Algorithm for Manufacturability of Supportless Parts Fabricated via LPBF

Lee

Yang

et al. 2023

Materials

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Recent advances in additive manufacturing have provided more freedom in the design of metal parts; hence, the prototyping of fluid machines featuring extremely complex geometries has been investigated extensively. The fabrication of fluid machines via additive manufacturing requires significant attention to part stability; however, studies that predict regions with a high risk of collapse are few. Therefore, a novel algorithm that can detect collapse regions precisely is proposed herein. The algorithm reflects the support span over the faceted surface via propagation and invalidates overestimated collapse regions based on the overhang angle. A heat exchanger model with an extremely complex internal space is adopted to validate the algorithm. Three samples from the model are extracted and their prototypes are fabricated via laser powder bed fusion. The results yielded by the fabricated samples and algorithm with respect to the sample domain are compared. Regions of visible collapse identified on the surface of the fabricated samples are predicted precisely by the algorithm. Thus, the supporting span reflected by the algorithm provides an extremely precise prediction of collapse.

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“…Nonetheless, when it comes to 3D-printed high-precision metal structures, the L-PBF barely struggle to meet the precision fabrication needs of miniature structures. It is due to that the L-PBF remains challenging on as-printed good surface roughness, especially for the overhanging structures [ 31 , 32 ]. In contrast, the SLA-printed structures have better surface roughness and geometric accuracy [ 33 ].…”

Section: Introductionmentioning

confidence: 99%

Convertible Thermal Meta-Structures via Hybrid Manufacturing of Stereolithography Apparatus 3D Printing and Surface Metallization for Thermal Flow Manipulation

Zhang

Deng

et al. 2022

Polymers

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For manipulating heat flow according to human desire, thermal metamaterial structures (meta-structures) have attracted growing interest. Based on the transformation thermotics and the effective medium approximation theory, we designed and fabricated a convertible thermal meta-structural device to demonstrate that multiple different heat-flow manipulations could be conducted using a single thermal meta-structural device. The convertible meta-structures were designed by discretizing a two-dimensional plane and separating multiple square unit modules with stripe-shaped dissimilar materials of the Polydimethylsiloxane (PDMS) and solid resin with surface metallized copper (Cu). The convertible thermal meta-structure device with a relatively high geometric accuracy was fabricated via a proposed hybrid manufacturing path of “Stereolithography Apparatus (SLA) 3D printing—electroless plating—electroplating—thermally insulated packaging”. The thermal manipulation features were numerically simulated and preliminarily verified by experimental testing. Using multiple dispersed square unit modules to replace an annular region of the thermal meta-structure exhibited different thermal flow functions, including thermal cloak, thermal concentration, thermal rotation, and thermal dispersion, through the unique geometric design of the heat-flow transfer direction within each module. By rotating each square unit module at a specific angle and arranging the modules, similar to a “jigsaw puzzle”, the convertibility among different thermal manipulation functions was achieved. This path is anticipated to provide a new strategy for multifunctional meta-structures in thermo-physics and its potential engineering applications.

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Effect of processing parameters on overhanging surface roughness during laser powder bed fusion of AlSi10Mg

Cited by 50 publications

References 21 publications

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

Facet Connectivity-Based Estimation Algorithm for Manufacturability of Supportless Parts Fabricated via LPBF

Convertible Thermal Meta-Structures via Hybrid Manufacturing of Stereolithography Apparatus 3D Printing and Surface Metallization for Thermal Flow Manipulation

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