Investigation of processing windows in additive manufacturing of AlSi10Mg for faster production utilizing data-driven modeling

Engelhardt, Andreas P.; Kahl, Matthias; Richter, Julia; Krooß, P.; Kroll, Andreas; Niendorf, Thoralf

doi:10.1016/j.addma.2022.102858

Cited by 10 publications

(21 citation statements)

References 37 publications

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“…Manufacturing of the samples was inspired by a previous study conducted by some of the present authors, investigating processing windows for a PBF-LB/M-processed aluminum alloy AlSi10Mg [ 27 ]. This approach enables a direct comparison of the processing windows of both materials.…”

Section: Methodsmentioning

confidence: 99%

“…This approach enables a direct comparison of the processing windows of both materials. Since the manufacturing conditions are mostly identical to the previous study [ 27 ], only the main details and differences are given in the following. Using a constant layer thickness

µm, samples with different combinations of the process parameters laser power

, scan speed

, and hatching distance

were manufactured.…”

Section: Methodsmentioning

confidence: 99%

“…Considering the parameter ranges given in Table 1 ,

parameter combinations were determined. The parameter ranges were based on the ranges of the previous study [ 27 ]. Considering other studies from literature investigating PBF-LB/M-processed 42CrMo4 [ 15 , 16 ], a lower minimum value of

and a higher minimum value of

were chosen in the present study.…”

Section: Methodsmentioning

confidence: 99%

“…Considering other studies from literature investigating PBF-LB/M-processed 42CrMo4 [ 15 , 16 ], a lower minimum value of

and a higher minimum value of

were chosen in the present study. Moreover, the upper value of

was limited in an attempt to avoid a special defect type named stripe pores that occurred in the previous study (stripe pores are a special form of LoF caused by a too low overlap between adjacent scan tracks due to a wide

) [ 27 ]. The resulting parameter combinations of the LHD cover a broad range of energy density

from

J/mm 3 up to

J/mm 3 .…”

Section: Methodsmentioning

confidence: 99%

“…Instead, it is investigated whether the 3MA variables correlate with the PBF-LB/M process parameters of laser power, scanning speed and hatch distance. These parameters already were the focal point of a previous study on AlSi10Mg [ 27 ], where a direct correlation with porosity could be elaborated. In order to ensure that a correlation between the process parameters and porosity is also present for the 42CrMo4 samples in focus, this question is investigated likewise in present work.…”

Section: Introductionmentioning

confidence: 97%

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Pathways toward the Use of Non-Destructive Micromagnetic Analysis for Porosity Assessment and Process Parameter Optimization in Additive Manufacturing of 42CrMo4 (AISI 4140)

Engelhardt,

Wegener,

Niendorf

2024

Materials

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Laser-based powder bed fusion of metals (PBF-LB/M) is a widely applied additive manufacturing technique. Thus, PBF-LB/M represents a potential candidate for the processing of quenched and tempered (Q&T) steels such as 42CrMo4 (AISI 4140), as these steels are often considered as the material of choice for complex components, e.g., in the toolmaking industry. However, due to the presence of process-induced defects, achieving a high quality of the resulting parts remains challenging in PBF-LB/M. Therefore, an extensive quality inspection, e.g., using process monitoring systems or downstream by destructive or non-destructive testing (NDT) methods, is essential. Since conventionally used downstream methods, e.g., X-ray computed tomography, are time-consuming and cost-intensive, micromagnetic NDT measurements represent an alternative for ferromagnetic materials such as 42CrMo4. In this context, 42CrMo4 samples were manufactured by PBF-LB/M with different process parameters and analyzed using a widely established micromagnetic measurement system in order to investigate potential relations between micromagnetic properties and porosity. Using multiple regression modeling, relations between the PBF-LB/M process parameters and six selected micromagnetic variables and relations between the process parameters and the porosity were assessed. The results presented reveal first insights into the use of micromagnetic NDT measurements for porosity assessment and process parameter optimization in PBF-LB/M-processed components.

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Section: Methodsmentioning

confidence: 99%

µm, samples with different combinations of the process parameters laser power

, scan speed

, and hatching distance

were manufactured.…”

Section: Methodsmentioning

confidence: 99%

“…Considering the parameter ranges given in Table 1 ,

and a higher minimum value of

were chosen in the present study.…”