Investigation of the in situ thermal conductivity and absorption behavior of nanocomposite powder materials in laser powder bed fusion processes

Pannitz, Oliver; Lüddecke, Arne; Kwade, Arno; Sehrt, Jan T.

doi:10.1016/j.matdes.2021.109530

Cited by 10 publications

(10 citation statements)

References 34 publications

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“…Hupfeld et al [28,29,32] presented a simplified scaling diagram for NP supporting on micro powders, link in NP particle size, surface coverage (surf%), and vol% as a prerequisite to creating very well defined, highly dispersed submonolayer NP coatings on PA12 and TPU, including the comparison between wet and dry coating. Pannitz et al [39] showed that coating SiC NPs or few-layer graphene (FLG) NPs on stainless steel powder feedstocks decreases the laser reflectivity of the powder feedstock and increases the thermal conductivity of the material during processing, leading to a rapid heat dissipation into the already solidified underlying layers during the melting of next powder layer. These different studies show the importance of measuring the physical and chemical properties of NPs before producing the additivated metal and polymer powder feedstocks to probe correlations between NP property, supported powder property, and the behavior along the process chain during ILS.…”

Section: Additivation Of Nps On As-produced Metal and Polymer Powder Feedstocksmentioning

confidence: 99%

“…The chemical composition of an unmodified metal or polymer powder feedstock directly affects the laser interaction, process window, microstructural formations, and as-built part properties [2,3,35]. These properties can be further affected by NPs' chemical composition, supported amount, and surface coverage levels [29][30][31][32][33]38,39]. In this ILS, the chemical composition of powder feedstock is recommended to be measured by XRF and ICP-OES.…”

Section: Chemical Compositionmentioning

confidence: 99%

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Nanoparticle Additivation Effects on Laser Powder Bed Fusion of Metals and Polymers—A Theoretical Concept for an Inter-Laboratory Study Design All Along the Process Chain, Including Research Data Management

et al. 2021

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In recent years, the application field of laser powder bed fusion of metals and polymers extends through an increasing variability of powder compositions in the market. New powder formulations such as nanoparticle (NP) additivated powder feedstocks are available today. Interestingly, they behave differently along with the entire laser powder bed fusion (PBF-LB) process chain, from flowability over absorbance and microstructure formation to processability and final part properties. Recent studies show that supporting NPs on metal and polymer powder feedstocks enhances processability, avoids crack formation, refines grain size, increases functionality, and improves as-built part properties. Although several inter-laboratory studies (ILSs) on metal and polymer PBF-LB exist, they mainly focus on mechanical properties and primarily ignore nano-additivated feedstocks or standardized assessment of powder feedstock properties. However, those studies must obtain reliable data to validate each property metric’s repeatability and reproducibility limits related to the PBF-LB process chain. We herein propose the design of a large-scale ILS to quantify the effect of nanoparticle additivation on powder characteristics, process behavior, microstructure, and part properties in PBF-LB. Besides the work and sample flow to organize the ILS, the test methods to measure the NP-additivated metal and polymer powder feedstock properties and resulting part properties are defined. A research data management (RDM) plan is designed to extract scientific results from the vast amount of material, process, and part data. The RDM focuses not only on the repeatability and reproducibility of a metric but also on the FAIR principle to include findable, accessible, interoperable, and reusable data/meta-data in additive manufacturing. The proposed ILS design gives access to principal component analysis (PCA) to compute the correlations between the material–process–microstructure–part properties.

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Section: Additivation Of Nps On As-produced Metal and Polymer Powder Feedstocksmentioning

confidence: 99%

Section: Chemical Compositionmentioning

confidence: 99%

Nanoparticle Additivation Effects on Laser Powder Bed Fusion of Metals and Polymers—A Theoretical Concept for an Inter-Laboratory Study Design All Along the Process Chain, Including Research Data Management

et al. 2021

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“…In this case, isolated pores were predominantly observed at a decreased velocity (1.2709 feedstock, IOB/1.2709). The low number of defects and the extended process window with FLG/1.2709 was attributable to the improved reflectance behavior and the possible increased heat conduction by the nanoparticle coating, which was already examined in more detail with an FLG/1.4404 material combination in a previous publication [26].…”

mentioning

confidence: 76%

“…An increasing absorption was observed with the addition of smaller particles. In a previous publication of this research group, the influence of coated stainless steel powders using SiC nanoparticles and few-layer graphene was investigated [26]. Consequently, increasing surface roughness and a macroscopically darker appearance of the metal powder could be observed.…”

Section: Laser Absorption Of Metal Powdersmentioning

confidence: 99%

“…Accordingly, a reduction in reflectance of up to 30% could be achieved. The degree of absorption of a powder material significantly depends on the PSD, morphology, surface roughness, and optical appearance (e.g., color) [26,28,35]. Due to the consistent results of the PSD, the cause is not attributable to a change in particle size.…”

Section: Laser Reflectance Of the Feedstocksmentioning

confidence: 99%

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Improved Process Efficiency in Laser-Based Powder Bed Fusion of Nanoparticle Coated Maraging Tool Steel Powder

et al. 2021

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Research and development in the field of metal-based additive manufacturing are advancing steadily every year. In order to increase the efficiency of powder bed fusion of metals using a laser beam system (PBF LB/M), machine manufacturers have implemented extensive optimizations with regard to the laser systems and build volumes. However, the optimization of metallic powder materials using nanoparticle additives enables an additional improvement of the laser–material interaction. In this work, tool steel 1.2709 powder was coated with silicon carbide (SiC), few-layer graphene (FLG), and iron oxide black (IOB) on a nanometer scale. Subsequently, the feedstock material and the modified powder materials were analyzed concerning the reflectance of the laser radiation and processed by PBF-LB/M in a systematic and consistent procedure to evaluate the impact of the nano-additivation on the process efficiency and mechanical properties. As a result, an increased build rate is achieved, exhibiting a relative density of 99.9% for FLG/1.2709 due to a decreased reflectance of this modified powder material. Furthermore, FLG/1.2709 provides hardness values after precipitation hardening with only aging comparable to the original 1.2709 material and is higher than the SiC- and IOB-coated material. Additionally, the IOB coating tends to promote oxide-formation and lack-of-fusion defects.

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A review on nanomaterial-based additive manufacturing: dynamics in properties, prospects, and challenges

Rahman,

Islam,

Dip

et al. 2023

Prog Addit Manuf

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The incorporation of nanomaterials has revolutionized the field of additive manufacturing. The combination of additive manufacturing technology with nanomaterials has significantly broadened the scope of materials available for modern and innovative applications in various fields, including healthcare, construction, food processing, and the textile industry. By integrating nanomaterials into additive manufacturing, the manufacturing process can be enhanced, and the properties of materials can be improved, enabling the fabrication of intricate structures and complex shapes. This review provides a comprehensive overview of the latest research on additive manufacturing techniques that utilize nanomaterials. It covers a wide range of nanomaterials employed in additive manufacturing and presents recent research findings on their incorporation into various categories of additive manufacturing, highlighting their impact on the properties of the final product. Moreover, the article discusses the potential of nanomaterial-based additive manufacturing technologies to revolutionize the manufacturing industry and explores the diverse applications of these techniques. The review concludes by outlining future research directions and focusing on addressing current challenges to enhance the overall efficiency and effectiveness of nanomaterial-based additive manufacturing. Graphical abstract

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Investigation of the in situ thermal conductivity and absorption behavior of nanocomposite powder materials in laser powder bed fusion processes

Cited by 10 publications

References 34 publications

Nanoparticle Additivation Effects on Laser Powder Bed Fusion of Metals and Polymers—A Theoretical Concept for an Inter-Laboratory Study Design All Along the Process Chain, Including Research Data Management

Nanoparticle Additivation Effects on Laser Powder Bed Fusion of Metals and Polymers—A Theoretical Concept for an Inter-Laboratory Study Design All Along the Process Chain, Including Research Data Management

Improved Process Efficiency in Laser-Based Powder Bed Fusion of Nanoparticle Coated Maraging Tool Steel Powder

A review on nanomaterial-based additive manufacturing: dynamics in properties, prospects, and challenges

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