Influence of process parameters on part quality and mechanical properties for DMLS and SLM with iron-based materials

Delgado, Jordi; Ciurana, Joaquim; Rodrı́guez, Ciro A.

doi:10.1007/s00170-011-3643-5

Cited by 248 publications

(145 citation statements)

References 15 publications

(16 reference statements)

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“…A similar inverse relationship between scan speed and hardness was also found by Kempen et al [1], Delgado et al [5], and Song et al [11] for several types of material on several AM systems. The lower hardness at the higher scan speed could be the result of insufficient melting of the powder (i.e., the laser travels too fast to thoroughly melt all powder particles).…”

Section: Hardnesssupporting

confidence: 64%

“…Sun et al found that the density of titanium alloy (Ti-6Al-4V) increased with decreasing scan speed [2]. In their comparative study of two AM systems, Delgado et al observed that while one system resulted in reduced hardness and ultimate tensile strength (UTS) with increased scan speed, the other systems did not result in any significant difference in either hardness or UTS [5].…”

Section: Changing Scan Speedmentioning

confidence: 98%

“…Delgado et al assessed the impact of changing the layer thickness on two different AM systems with corresponding stainless steel powders [5]. One system produced parts with lower hardness with increasing layer thickness, while the other system did not result in a significant change in hardness with increasing layer thickness.…”

Section: Changing Layer Thicknessmentioning

confidence: 99%

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The effects of laser powder bed fusion process parameters on material hardness and density for nickel alloy 625

Brown¹,

Jacob²,

Possolo³

et al. 2018

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The goal of this study was to investigate the relationship between mechanical and material properties (including density) of manufactured nickel super alloy (IN625) using a laser powder bed fusion process and three process parameters: laser power, hatch distance, and scan speed. Hardness of the manufactured blocks was measured as a representative of the mechanical properties. Density measurements were carried out using the pyncometry method. Three sets of blocks were manufactured using IN625 metal powder (nitrogen gas atomized) on a laser powder bed fusion machine. Different combinations of process parameters yielded different energy densities for each block for the three builds. The laser scan speed, laser power, hatch distance, and energy density all had statistically significant relationships with hardness. The average bulk density increased non-linearly with increasing values of energy density. A similar trend was in the hardness data. The results of this study served as a guide to determine the range of parameters yielding acceptable material properties for the investigation of process parameter sensitivities during a subsequent IN625 round robin study.

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Section: Hardnesssupporting

confidence: 64%

Section: Changing Scan Speedmentioning

confidence: 98%

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The effects of laser powder bed fusion process parameters on material hardness and density for nickel alloy 625

Brown¹,

Jacob²,

Possolo³

et al. 2018

View full text Add to dashboard Cite

show abstract

“…Ranking the parameters in order of importance is critical to limiting the scope of design of experiments (DOE) studies that are a common approach to identifying sets of parameters that optimize material properties such as density. An example of the use of DOE methods to rank parameters is given in the main effects analysis of Delgado et al (2012). It is not unusual for DOEs to include hundreds of samples to reach an optimal set of process parameters, making such investigations time consuming and expensive.…”

Section: Introductionmentioning

confidence: 99%

Density of additively-manufactured, 316L SS parts using laser powder-bed fusion at powers up to 400 W

Kamath

El-Dasher

Gallegos

et al. 2014

Int J Adv Manuf Technol

314

136

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Selective laser melting is a powder-based, additive-manufacturing process where a threedimensional part is produced, layer by layer, by using a high-energy laser beam to fuse the metallic powder particles. A particular challenge in this process is the selection of appropriate process parameters that result in parts with desired properties. In this study, we describe an approach to selecting parameters for high density (>99%) parts using 316L stainless steel. Though there has been significant success in achieving near-full density for 316L parts, this work has been limited to laser powers <225W. We discuss how we can exploit prior knowledge, design of computational experiments using a simple model of laser melting, and single-track experiments to determine the process parameters for use at laser powers up to 400W. Our results show that, at higher power values, there is a large range of scan speeds over which the relative density remains >99%, with the density reducing rapidly at high speeds due to insufficient melting, and less rapidly at low speeds due to the effect of voids created as the process enters keyhole mode.

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“…A comparison study of different powder grades (three different particle size distribution) also has been demonstrated with the aim of fabrication of high density SS 316L parts [24]. Whilst more work has been reported on how to achieve high density parts [25,26], there are few studies that discuss how to achieve such porous parts. Such examples include the work conducted by Cijun et.…”

Section: Introductionmentioning

confidence: 99%

Electrical conductivity and porosity in stainless steel 316L scaffolds for electrochemical devices fabricated using selective laser sintering

Ibrahim

Brandon

2016

Materials & Design

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Battery electrode microstructures must be porous, to provide a large active surface area to facilitate fast charge transfer kinetics. In this work, we describe how a novel porous electrode scaffold, made from stainless steel 316L powder can be fabricated using selective laser sintering by proper selection of process parameters. Porosity, electrical conductivity and optical microscopy measurements were used to investigate the properties of fabricated samples. Our results show that a laser energy density between 1.50-2.00 J/mm 2 leads to a partial laser sintering mechanism where the powder particles are partially fused together, resulting in the fabrication of electrode scaffolds with 10% or higher porosity. The sample fabricated using 2.00 J/mm 2 energy density (60W -1200 mm/s) exhibited a good electrical conductivity of 1.80 x 10 6 S/m with 15.61% of porosity. Moreover, we have observed the porosity changes across height for the sample fabricated at 60W and 600 mm/s, 5.70% from base and increasing to 7.12% and 9.89% for each 2.5 mm height toward the top surface offering graded properties ideal for electrochemical devices, due to the changing thermal boundary conditions. These highly porous electrode scaffolds can be used as an electrode in electrochemical devices, potentially improving energy density and life cycle.

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Influence of process parameters on part quality and mechanical properties for DMLS and SLM with iron-based materials

Cited by 248 publications

References 15 publications

The effects of laser powder bed fusion process parameters on material hardness and density for nickel alloy 625

The effects of laser powder bed fusion process parameters on material hardness and density for nickel alloy 625

Density of additively-manufactured, 316L SS parts using laser powder-bed fusion at powers up to 400 W

Electrical conductivity and porosity in stainless steel 316L scaffolds for electrochemical devices fabricated using selective laser sintering

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