Investigation and Optimization of the SLM and WEDM Processes’ Parameters for the AlSi10Mg-Sintered Part

Franczyk, Emilia; Machno, Magdalena; Zębala, Wojciech

doi:10.3390/ma14020410

Cited by 17 publications

(5 citation statements)

References 43 publications

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“…To obtain a homogenous surface and a reduced roughness, the process parameters which scan the outer boundary of parts should be optimized for each type of powder material. ANOVA method offers the opportunity to optimize the process parameters by obtaining an empiric mathematical model through mathematical combinations, statistical techniques, and the response surface methodology [41]. In addition, a common practice for post-processing the surfaces of the SLM parts are sandblasting with alumina, polishing with carborundum and ultrasonication.…”

Section: Discussionmentioning

confidence: 99%

Investigation onto the reliability of the selective laser melting process

Leordean

Cosma

Radu

et al. 2022

Preprint

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The paper aims to offer the readers knowledge and information, to support new implementation and use of the SLM technology for practical applications and to obtain good metal parts for end users. The SLM parameters and conditions were evaluated to set up a scale and estimate how reliable the SLM-AM process is, on a particular type of machine. The experimental research was carried out in the last years by the authors, using the Realizer 250 machine. Many times, there is a lack of repeatability and reliability of the SLM process. The paper is presenting a new method to evaluate the repeatability and the surface roughness, when processing four types of powder materials, mainly for medical applications. Specimens were manufactured from four materials considered as being bio-metals: pure Titanium, Ti6Al7Nb, CoCr, and CoCrWMo. All these important features of the SLM parts were for seen by the authors in close relation with the mechanical characteristics of the parts. In this way, a good instrument is offered for further FEA applications, such as static and dynamic analysis. The main achievement of this paper is our proposed methodology, useful for a new user to design and analyse a specific practical SLM part. In this way, it will be possible for sure to manufacture that part by SLM, using the Realizer 250 machine, from one of the four types of materials, that the authors are presenting detailed data regarding their physical-mechanical properties.

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Section: Discussionmentioning

confidence: 99%

Investigation onto the reliability of the selective laser melting process

Leordean

Cosma

Radu

et al. 2022

Preprint

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“…However, efforts are still being made to improve its performance, parameters and the accuracy of the manufactured shapes. Experimental research is still being done to increase material removal rate (MRR), reduce tool wear (TW), and reduce surface roughness (SR) [2][3][4]. Additionally micro-holes requires high dimensional and shape accuracy without burrs and micro-cracks [5].…”

Section: Introductionmentioning

confidence: 99%

Analysis of the relationship between the properties of selected materials and the parameters of the EDD process

Trajer

2023

Materials Research Proceedings

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Abstract. The thermophysical properties of the electrodes material significantly impact performance of the electrical discharge machining (EDM). The aim of this article was to investigate the influence of thermophysical properties of selected materials on the EDM process. The effect of the thermophysical properties of these materials on process efficiency factors (material removal rate, linear tool wear) and hole geometry (aspect ratio, radial overcut) was analyzed. The results showed that selected thermophysical properties of the workpiece, such as thermal conductivity, melting point, have the most significant impact on the electro-erosion process. Optimal result parameters (material removal rate: 2.58 mm3/min, linear tool wear: 4.95 mm, aspect ratio: 8.00, radial overcut: 0.046 mm) and no presence of “bottom cone” were obtained for EDM drilling in Inconel 718 and similarly for AISI 1045 steel. On the other end were high resistance alloys such as tungsten carbide and copper alloy.

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“…Due to the complexity of the physical phenomena occurring in the SLM process, identifying the impact of parameters such as laser power, scan speed, scan strategy, hatch spacing, and material or powder particles on the surface integrity and the geometric accuracy of the manufacturing parts [5][6][7][8][9] is difficult. The research conducted on the optimization of the SLM process [10][11][12][13] improved the properties of the manufactured parts; however, achieving a roughness below 1 micron, which is very often required in industrial applications, is still a challenge. Despite the many advantages of using SLM in the production of parts for the aerospace or power industry [14,15], the high surface roughness, dimensional and geometric inaccuracy [16,17], defects of surface layers such as balling effect [18,19], power adhesion [20], and microcracks [21,22] in many cases require the use of additional post-processing technologies [23].…”

Section: Introductionmentioning

confidence: 99%

Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy

Oniszczuk-Świercz

Świercz

2023

Materials

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The Selective laser melting (SLM) technology of recent years allows for building complex-shaped parts with difficult-to-cut materials such as Ti6Al4V alloy. Nevertheless, the surface integrity after SLM is characterized by surface roughness and defects in the microstructure. The use of additional finishing technology, such as machining, laser polishing, or mechanical polishing, is used to achieve desired surface properties. In this study, improving SLM Ti6Al4V alloy surface integrity using wire electrical discharge machining (WEDM) is proposed. The influence of finishing WEDM cuts and the discharge energy on the surface roughness parameters Sa, Svk, Spk, and Sk and the composition of the recast layer were investigated. The proposed finishing technology allows for significant improvement of the surface roughness by up to 88% (from Sa = 6.74 µm to Sa = 0.8 µm). Furthermore, the SEM analyses of surface morphology indicate improving surface integrity properties by removing the balling effect, unmelted particles, and the presence of microcracks. EDS analysis of the recast layer indicated a significant influence of discharge energy and the polarization of the electrode on its composition and thickness. Depending on the used discharge energy and the number of finishing cuts, changes in the composition of the material in the range of 2 to 10 µm were observed.

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Investigation and Optimization of the SLM and WEDM Processes’ Parameters for the AlSi10Mg-Sintered Part

Cited by 17 publications

References 43 publications

Investigation onto the reliability of the selective laser melting process

Investigation onto the reliability of the selective laser melting process

Analysis of the relationship between the properties of selected materials and the parameters of the EDD process

Effects of Wire Electrical Discharge Finishing Cuts on the Surface Integrity of Additively Manufactured Ti6Al4V Alloy

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