Investigation of laser powder bed fusion manufacturing and post-processing for surface quality of as-built 17-4PH stainless steel

Yang, Kyung-Tae; Kim, Min-Kyeom; Kim, Dong-Won; Suhr, Jonghwan

doi:10.1016/j.surfcoat.2021.127492

Cited by 27 publications

(15 citation statements)

References 26 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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“…While some degree of porosity is acceptable because it is unavoidable, hot ripping and cracking must be avoided. The most serious problems that lower the as-built component's quality in LPBF are hot tearing and cracks [63][64][65]. In general aspect, low constitutional supercooling give rise to the formation of columnar grains columnar grains but temperature gradient is still substantial, making them particularly susceptible to hot ripping.…”

Section: Laser-based Additive Manufacturingmentioning

confidence: 99%

Advancement of Magnesium and Aluminum Alloys in the Role of Additive Manufacturing

Sharma¹,

Grewal²,

Saxena³

et al. 2022

Preprint

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Magnesium and Aluminum alloys continue to be important in the context of modern and lightweight technologies. With the advancement of additive manufacturing (AM), components can be produced directly in a net shape, widen up the usage of magnesium and aluminum alloys as well as holding new ideas for the application of unique physical structures made feasible by 3D printing. Laser-based approach, one of the metal additive manufacturing (AM) methods, enables the formation of arbitrary 3D structures. With promising findings, research in this area is advancing quickly, bringing up a variety of potential applications in both the scientific and industrial sectors. Complex structures can now be manufactured easily utilizing AM technologies to meet the pre-requisite objectives like reduced part numbers, greater functionality, and lightweight, among others. AM has the ability to meet demands by lowering costs and speeding up the manufacturing process. Due to their popularity in numerous high-value applications, aluminum, and magnesium alloys are one of the key material systems being researched in the laser-based additive manufacturing approaches. The review here aims to comprehensively examine the additive manufacturing of magnesium and aluminum alloys, highlighting the influence of the laser-based additive manufacturing approach on the mechanical characteristics, microstructure, and tribological performance of magnesium and aluminum alloys.

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“…Even though support structure optimization has been investigated in detail by many researchers [12,32,33], specific investigations on the influence of support structure removal strategies had not been carried out in L-PBF research until now. Instead, the focus was mostly on improving the surface properties of the final components in achieving the required surface roughness specifications [44,45]. This was mostly attributed to the difficulties involved in dealing with miniature-sized specimen geometries.…”

Section: Support Structure Design Optimization and Support Removal Strategiesmentioning

confidence: 99%

An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents

et al. 2021

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One of the fundamental challenges in L-PBF of filigree geometries, such as aortic stents used in biomedical applications, is the requirement for a robust yet easily removable support structure that allows each component to be successfully fabricated without distortion. To solve this challenge, an integrative experimental approach was attempted in the present study by identifying an optimal support structure design and an optimized support removal strategy for this design. The specimens were manufactured using four different support structure designs based on the geometry exposed to the laser beam during the L-PBF. Support removal procedures included sand blasting (SB), glass bead blasting (GB), and electrochemical polishing (ECP). The two best-performing designs (line and cross) were chosen due to shorter lead times and lower material consumption. As an additional factor that indicates a stable design, the breaking load requirement to remove the support structures was determined. A modified line support with a 145° included angle was shown to be the best support structure design in terms of breaking load, material consumption, and manufacturing time. All three procedures were used to ensure residue-free support removal for this modified line support design, with ECP proving to be the most effective.

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Investigation of laser powder bed fusion manufacturing and post-processing for surface quality of as-built 17-4PH stainless steel

Cited by 27 publications

References 26 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

Advancement of Magnesium and Aluminum Alloys in the Role of Additive Manufacturing

An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents

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