Laser powder bed fusion: a state-of-the-art review of the technology, materials, properties &amp; defects, and numerical modelling

Chowdhury, Sohini; Nirsanametla, Yadaiah; Prakash, Chander; Ramakrishna, Seeram; Dixit, Saurav; Gulta, Lovi Raj; Buddhi, Dharam

doi:10.1016/j.jmrt.2022.07.121

Cited by 179 publications

(63 citation statements)

References 376 publications

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“…3a). In this case, the poor metallurgical bond is caused by balling phenomena [3], visible in the top surface (Fig. 5a) where the tracks are clearly discontinuous.…”

Section: Discussionmentioning

confidence: 96%

“…The printing was stopped, excepted for sample 7. Despite the wide range of Ed (52 -125 J/mm 3 ), the low P could not generate sufficient liquid phase for the powders to bond together, resulting in poor densification [3]. The metallurgical bond between layers is also compromised, leading to the possible material tear out (Fig.…”

Section: Discussionmentioning

confidence: 99%

“…LPBF process involves complex physical phenomena, such as absorption and transmission of laser energy, rapid melting and solidification of material, microstructure evolution flow in a molten pool and material evaporation [2]. These complex phenomena may result in defects such as gas porosities, lack of fusion areas, cracks, spatters, key-hole porosities and balling [2][3][4][5]. Despite the problems and complexity faced during the process, the manufacturing of new alloys by LPBF has been growing over the recent years.…”

Section: Development and Processability Of Aisi S2 Tool Steel By Lase...mentioning

confidence: 99%

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Development and processability of AISI S2 tool steel by laser powder bed fusion

Saggionetto

2023

Materials Research Proceedings

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Abstract. Nowadays, the advantages of Laser Powder Bed Fusion (LPBF) technology attract both industry and researchers. Indeed, it is possible to build up complex geometrical parts with higher mechanical properties than those obtained by conventional methods. However, LPBF involves complex phenomena due to the high heating and cooling rates that lead to out-of-equilibrium conditions. For this reason, few metal alloys are easily processable up to now. Nevertheless, research on new steels by LPBF has been growing in recent years, in particular, regarding the development of tool steels. This work thus focuses on the development of the tool steel AISI S2 by LPBF. The process map has been investigated by varying the laser power from 100 to 250 W and the scan speed from 400 to 2000 mm/s. By combining surface analysis by means of profilometer observations, density measurements by pycnometry, defects characterization and quantification and investigations on the melt pool morphology, the best process window is selected to have fully dense, defect-free parts. Furthermore, this study allows to have comprehensive insights on the effect of the parameters on the type of defects generated during the manufacturing.

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“…3a). In this case, the poor metallurgical bond is caused by balling phenomena [3], visible in the top surface (Fig. 5a) where the tracks are clearly discontinuous.…”

Section: Discussionmentioning

confidence: 96%

Section: Discussionmentioning

confidence: 99%

Section: Development and Processability Of Aisi S2 Tool Steel By Lase...mentioning

confidence: 99%

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Development and processability of AISI S2 tool steel by laser powder bed fusion

Saggionetto

2023

Materials Research Proceedings

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“…The tendency toward patient-specific medical devices has increased the use of Ti6Al4V 3D-printed surgical implants ( Chowdhury et al, 2022 ; Lam et al, 2022 ; Tom et al, 2022 ). Several standards specify requirements for the minimum mechanical properties of Ti6AI4V alloys produced by additive manufacturing (ASTM-F3001-14, ISO 5832-3).…”

Section: Introductionmentioning

confidence: 99%

Experimental analysis and numerical fatigue life prediction of 3D-Printed osteosynthesis plates

Nakhaei¹,

Sterba²,

Foletti

et al. 2023

Front. Bioeng. Biotechnol.

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The trend towards patient-specific medical orthopedic prostheses has led to an increased use of 3D-printed surgical implants made of Ti6Al4V. However, uncertainties arise due to varying printing parameters, particularly with regards to the fatigue limit. This necessitates time-consuming and costly experimental validation before they can be safely used on patients. To address this issue, this study aimed to employ a stress-life fatigue analysis approach coupled with a finite element (FE) simulation to estimate numerically the fatigue limit and location of failure for 3D-printed surgical osteosynthesis plates and to validate the results experimentally. However, predicting the fatigue life of 3D components is not a new concept and has previously been implemented in the medical device field, though without experimental validation. Then, an experimental fatigue test was conducted using a proposed modification to the staircase method introduced in ISO 12107. Additionally, a FE model was developed to estimate the stress cycles on the plate. The stress versus number of cycles to failure curve (S-N) obtained from the minimum mechanical properties of 3D-printed Ti6AI4V alloy according to ASTM F3001-14 to predict the fatigue limit. The comparison between experimental results and fatigue numerical predictions showed very good agreement. It was found that a linear elastic FE model was sufficient to estimate the fatigue limit, while an elastic-plastic model led to an accurate prediction throughout the implant’s cyclic life. The proposed method has great potential for enhancing patient-specific implant designs without the need for time-consuming and costly experimental regulatory testing.

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“…Image of voids in the structure printed by extrusion method: a) filament orientation in 0/90 layers, b) filament orientation in 45/-45 layersThe presence of voids in the structure also affects the formation of stress concentrators, which results in a weakened structure of printed objects. In the case of methods (such as sintering), the density of printed objects is high, resulting in substantially higher strength of printed objects compared to processing by conventional technologies[45].…”

mentioning

confidence: 99%

Challenges in Tensile Testing of Thermoplastic Composites Reinforced with Chopped Carbon Fibre Produced by Fused Filament Fabrication Method

Majko¹,

Vaško²,

Handrik³

et al. 2023

Manufacturing Technology

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Additive manufacturing is a relatively new technology that has recently undergone noticeable development, which includes several types of technologies based on the gradual deposition of material in layers. The most widespread method is Fused Filament Fabrication, which belongs to an extrusion technique. The typical feature of extrusion methods is material deposition in the filaments form. Therefore, printer users cannot apply the same approach to products as with conventional technologies. The authors of the paper have been working with the mentioned technology for several years. The primary goal of the research is the investigation how printing parameters affect the mechanical properties of laminates reinforced with chopped carbon fibres. Based on experience and knowledge, the authors report in this article the most common challenges encountered in the preparation process of specimens for tensile testing. This knowledge can also help ordinary users of 3D printers, who also face these challenges without being aware of the impact of these pitfalls on mechanical properties. Tensile testing Additive manufacturingFused Filament Fabrication, Chopped carbon fiber

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Laser powder bed fusion: a state-of-the-art review of the technology, materials, properties & defects, and numerical modelling

Cited by 179 publications

References 376 publications

Development and processability of AISI S2 tool steel by laser powder bed fusion

Development and processability of AISI S2 tool steel by laser powder bed fusion

Experimental analysis and numerical fatigue life prediction of 3D-Printed osteosynthesis plates

Challenges in Tensile Testing of Thermoplastic Composites Reinforced with Chopped Carbon Fibre Produced by Fused Filament Fabrication Method

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