Experimental and analytical investigations of AlSi10Mg, stainless steel, Inconel 625 and Ti-6Al-4V porous materials printed via powder bed fusion

Gotoh, Ryohei; Furst, Benjamin; Roberts, Scott; Cappucci, Stefano; Daimaru, Takuro; Sunada, Eric

doi:10.1007/s40964-022-00269-8

Cited by 14 publications

(23 citation statements)

References 40 publications

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“…[22,26] Multiple studies-using various PBF-LB/M machines and materials-show that the process parameter settings influence DM's properties. [9][10][11][12][13][14][15][16][17][20][21][22][23][24][25][26][27] It is furthermore exhibited that these relations can be used to pre-print-predict, e.g., the RD by utilizing a design of experiment (DoE) approach. [12] For DMs made from Haynes 282 variations in properties depending on the applied process parameters are also demonstrated but these findings are yet nonquantified.…”

Section: Doi: 101002/adem202200469mentioning

confidence: 99%

“…[2,3,8,9] Process adaptations-either modifying the powder feedstock, or process and machine parameters-can be used to provoke randomly distributed porosity into PBF-LB/M components. [9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25][26][27][28] For the approach of process parameter adaptions, the formation of pores is driven by the controlled introduction of defects, e.g., lack of fusion. [9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25][26][27][28] In two previous studies so-called designed materials (DMs) were produced from the nickel-based superalloy Haynes 282 -UNS N07208 ).…”

mentioning

confidence: 99%

“…[9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25][26][27][28] For the approach of process parameter adaptions, the formation of pores is driven by the controlled introduction of defects, e.g., lack of fusion. [9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25][26][27][28] In two previous studies so-called designed materials (DMs) were produced from the nickel-based superalloy Haynes 282 -UNS N07208 ). [9,22,26] Their open porosity was fabricated by lowering laser power, increasing scan speed, hatch distance, or layer thickness in comparison to a standard process parameter set.…”

mentioning

confidence: 99%

“…[9,22,26] Multiple studies analyzed DM's morphology regarding porosity (or RD), pore, and strut size. [9][10][11][12][13][14][15][16][17]20,21,[23][24][25]27] These investigations focus on process parameter influences and have not assessed the property's scatter. [9][10][11][12][13][14][15][16][17]20,21,[23][24][25]27] Determining the RD (or porosity) by calculating the ratio of dimensions and weight is a commonly used method for porous samples.…”

mentioning

confidence: 99%

“…[9][10][11][12][13][14][15][16][17]20,21,[23][24][25]27] These investigations focus on process parameter influences and have not assessed the property's scatter. [9][10][11][12][13][14][15][16][17]20,21,[23][24][25]27] Determining the RD (or porosity) by calculating the ratio of dimensions and weight is a commonly used method for porous samples. [14,16,[20][21][22][23][24]26] For the pore and strut size, the digital assessment via microcomputed…”

mentioning

confidence: 99%

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Pre‐Print‐Prediction of Morphological Properties for Designed Materials Manufactured via Laser‐Based Powder Bed Fusion of Metals on a Multi‐Laser Machine

et al. 2022

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The energy market for large gas turbines (LGTs) is in a transition toward improved sustainability. [1][2][3][4] Two approaches are in focus to reach this goal: Efficiency increases for LGTs powered with fossil fuels, or combusting alternative fuels such as hydrogen. [1][2][3] These developments go in hand with aggressive thermal conditions for hot gas path components in LGT's combustion and turbine section. [2,3,[5][6][7][8] Therefore, the cooling design of hot gas path components needs to be improved. [2,3,[5][6][7][8] Transpiration cooling is an efficient way to enable part operation in high-temperature environments. [5,6] To achieve the cooling effect, compressed air effuses from the cold gas side through an open-porous part to the hot gas side. [5,6] The outflowing coolant covers the hot component surface with a protective cooling film. [5,6] Geometrically defined or randomly distributed open porosity can be utilized for this cooling method. [5,6] Laser-based powder bed fusion of metals (PBF-LB/M) is an additive manufacturing technology for the production of sophisticated geometries. [2,3,8,9] Its ability to process nickel-based superalloys makes it suitable for high-temperature applications. [2,3,8,9] Process adaptations-either modifying the powder feedstock, or process and machine parameters-can be used to provoke randomly distributed porosity into PBF-LB/M components. [9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25][26][27][28] For the approach of process parameter adaptions, the formation of pores is driven by the controlled introduction of defects, e.g., lack of fusion. [9][10][11][12][13][14][15][16][17][18][19][20][21][22][23][24][25][26][27][28] In two previous studies so-called designed materials (DMs) were produced from the nickel-based superalloy Haynes 282 -UNS N07208 ). [9,22,26] Their open porosity was fabricated by lowering laser power, increasing scan speed, hatch distance, or layer thickness in comparison to a standard process parameter set. [9,22,26] Multiple studies analyzed DM's morphology regarding porosity (or RD), pore, and strut size. [9][10][11][12][13][14][15][16][17]20,21,[23][24][25]27] These investigations focus on process parameter influences and have not assessed the property's scatter. [9][10][11][12][13][14][15][16][17]20,21,[23][24][25]27] Determining the RD (or porosity) by calculating the ratio of dimensions and weight is a commonly used method for porous samples. [14,16,[20][21][22][23][24]26] For the pore and strut size, the digital assessment via microcomputed

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Section: Doi: 101002/adem202200469mentioning

confidence: 99%

mentioning

confidence: 99%

mentioning

confidence: 99%

mentioning

confidence: 99%

mentioning

confidence: 99%

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Pre‐Print‐Prediction of Morphological Properties for Designed Materials Manufactured via Laser‐Based Powder Bed Fusion of Metals on a Multi‐Laser Machine

et al. 2022

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Effect of Process Variables on Microstructure, Flow, and Tensile Properties of Nickel‐Based Superalloys with Designed Porous Structures Manufactured by Laser‐Based Powder Bed Fusion

2023

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The nickel‐based superalloys Haynes 282 and Inconel 625 are processed using laser‐based powder bed fusion of metals (PBF‐LB/M) to manufacture designed materials (DMs) with configurable open‐porous morphology. Such structures can be utilized in large gas turbines, for example, as high‐frequency dampers, heat exchangers, and for transpiration cooling features. This research investigates the effects of the applied volume energy input and laser deflection angle (as calculated by position) on the macro‐ and microstructure and tensile and flow properties of DMs made from Haynes 282. Furthermore, a novel combination of DMs and cubic lattice structures made from Inconel 625 has been investigated regarding potential improvements. The substantial interface between the two features, DM and lattice structure, is visually analyzed using microcomputed tomography. The analysis of the hierarchical DMs reveals that the combination of lattice structures and DMs is manufacturable and has benefits in terms of mechanical strength while having less significant effects on flow properties.

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Advanced Support Structures in Metal Additive Manufacturing: A Comparative Analysis of Porous Media for Enhanced Part Quality and Removal Efficiency

Erol,

Gülletutan,

Günaydın

et al. 2024

Adv Eng Mater

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In laser powder bed fusion additive manufacturing support, structures are crucial for constructing overhang features and maintaining dimensional accuracy. However, traditional support structures exhibit inherent drawbacks, including compromised surface quality, prolonged post‐processing times, and other challenging requirements. This study investigates innovative approaches to address these issues by analyzing two types of specimens—cuboid and lap shear. The cuboid samples explore the manipulation of process parameters to adjust energy densities, transitioning from powder to porous support structures, with porosity measurement assessment. Subsequently, a shear test specimen objectively evaluates porous support parameters alongside traditional block‐type support, analyzing their impact on removal force, distortion, and surface quality. Results reveal that optimized porous support structures surpass traditional counterparts, showcasing superior surface quality, reduced removal forces, and minimized part distortion. Specifically, the shear test demonstrates a 94.25% reduction in removal forces and a 33.67% decrease in upper part distortion. Moreover, the maximum surface roughness (Rz) improves by 22.8% with the implementation of porous supports. By introducing a methodology for comparative analyses of measurable performance indicators, this research enhances understanding of support structure dynamics in additive manufacturing, facilitating advancements in efficiency and quality within the field.This article is protected by copyright. All rights reserved.

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Experimental and analytical investigations of AlSi10Mg, stainless steel, Inconel 625 and Ti-6Al-4V porous materials printed via powder bed fusion

Cited by 14 publications

References 40 publications

Pre‐Print‐Prediction of Morphological Properties for Designed Materials Manufactured via Laser‐Based Powder Bed Fusion of Metals on a Multi‐Laser Machine

Pre‐Print‐Prediction of Morphological Properties for Designed Materials Manufactured via Laser‐Based Powder Bed Fusion of Metals on a Multi‐Laser Machine

Effect of Process Variables on Microstructure, Flow, and Tensile Properties of Nickel‐Based Superalloys with Designed Porous Structures Manufactured by Laser‐Based Powder Bed Fusion

Advanced Support Structures in Metal Additive Manufacturing: A Comparative Analysis of Porous Media for Enhanced Part Quality and Removal Efficiency

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