Manufacturing of thin wall structures in AlSi10Mg alloy by laser powder bed fusion through process parameters

Calignano, Flaviana; Cattano, Giulio; Manfredi, Diego

doi:10.1016/j.jmatprotec.2018.01.029

Cited by 61 publications

(24 citation statements)

References 31 publications

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“…Considerable effort is invested in the development of thin walls and lattice structures, which enables one to achieve lightweight or increased specific surface area of the parts. [6][7][8][9][10][11] These features are essential for many applications, such as heat exchangers in the energy and gas sectors. A recent study conducted by Abele et al [12] focused on laser parameter optimization to achieve controlled porosity and permeability for applications, such as fuel cells, which require defined mass transport through thin wall structures.…”

Section: Introductionmentioning

confidence: 99%

Effect of the Process Gas and Scan Speed on the Properties and Productivity of Thin 316L Structures Produced by Laser-Powder Bed Fusion

Pauzon

Leicht

Klement

et al. 2020

Metall Mater Trans A

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The development of the laser powder bed fusion (L-PBF) process to increase its robustness and productivity is challenged by ambitious design optimizations, such as thin wall structures. In this study, in addition to the effect of commonly used gases as Ar and N2, increased laser scanning speed and new process gases, such as helium, were successfully implemented. This implementation allowed to build 316L stainless steel components with thin walls of 1 mm thickness with an enhanced build rate of 37 pct. The sample size effect and the surface roughness were held responsible for the reduction in strength (YS > 430 MPa) and elongation (EAB > 30 pct) for the 1 mm samples studied. Similar strength was achieved for all process gases. The increased scanning speed was accompanied by a more random texture, smaller cell size, and grain size factor along the building direction when compared to the material built with the standard laser parameters. Stronger preferential orientation 〈101〉 along the building direction was observed for material built with standard parameters. Finally, the use of helium as a process gas was successful and resulted in reduced cell size. This finding is promising for the future development of high strength 316L stainless steel built with high build rates.

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Section: Introductionmentioning

confidence: 99%

Effect of the Process Gas and Scan Speed on the Properties and Productivity of Thin 316L Structures Produced by Laser-Powder Bed Fusion

Pauzon

Leicht

Klement

et al. 2020

Metall Mater Trans A

View full text Add to dashboard Cite

show abstract

“…Each of these parameters can be changed independently, but the selection of the parameters generates a multi-variable problem. The main critical parameters considered in the literature are [9,40]: Beam offset (the diameter of the melted zone is usually larger than the laser diameter and is called spot diameter. In order to compensate the dimensional error due to spot diameter, the laser beam should be offset from the boundaries of the cross-section of the object and is called beam offset).…”

Section: Process Parametersmentioning

confidence: 99%

“…Energy density is the energy input of the laser beam per unit volume [31]. Unfortunately, this approach, which is aimed at characterizing the overall complexity of L-PBF processes by means of a single number, has been shown to be insufficient [9,32,49]. The EBM process involves complex physical mechanisms, and their understanding and description still represent a challenging task.…”

Section: Process Parametersmentioning

confidence: 99%

“…Bassoli et al [8] proposed an exploratory standardization of the procedure that has to be followed to develop a complete set of process parameters for the L-PBF of innovative alloys, new machines, or untested alloy/machine combinations. However, this procedure does not consider the possible numerical combinations of the process parameters that generate the same density energy values albeit with different results [9]. Moreover, the effect of the choice of the geometric parameters of the block support is not considered for the support structures [10].…”

Section: Introductionmentioning

confidence: 99%

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A Metal Powder Bed Fusion Process in Industry: Qualification Considerations

2019

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An additive manufacturing process should produce repeatable results as far as the properties of the material and the geometric dimensions that have to be adopted by a company as a production method are concerned. This represents a challenge for such high-volume sectors as the automotive industry, where quality and reliability are extremely important. One way of addressing this challenge is to qualify the process. A common framework has here been identified starting from the analysis of the factors that influence the stability of the result in the main phases of metal powder bed fusion (PBF) processes. A qualification procedure (QP), which offers possible solutions to help reduce risk factors, has been proposed. This procedure is independent of the industrial sectors, of which type of materials and metal PBF processes, and of the manufacturer of the used PBF system.

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“…Considering that only small production lots are produced per year and each testing machine is highly customized according to the specific requirements of each customer, the redesign lends itself well to production through metal AM systems. Because of the requirements of high dimensional accuracy, the laser powder bed fusion (L-PBF) technique is considered [22]. A comprehensive approach was proposed in which material distribution optimization, design for L-PBF, and design for assembly (DfA) are considered.…”

Section: Introductionmentioning

confidence: 99%

Additive Manufacturing Redesigning of Metallic Parts for High Precision Machines

et al. 2020

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The conventional approach to design and manufacturing often has geometries with an efficient material distribution. For the high-precision machines, that approach involves the design of heavy components that guarantees the stiffness requirements. However, the higher the weight of the part, the higher inertia it has. As a result, when the feed axes are accelerated, the inertial forces deform the machine components and the precision of the machine is reduced. This study investigated the designing for additive manufacturing (DfAM) and designing for assembly (DfA) to increase the material efficiency of components for high-precision applications. A new methodology which considered the design and manufacturing issues and machining as well is given. A comprehensive model for cost evaluation of the part is presented. The case study refers to the rails and the bracket that support and move the flying probe of a testing machine for micro-electromechanical systems (MEMS). The weight of the rails has been decreased by 32% and the components to be assembled have been reduced from 16 to 7. The optimized bracket is more than 50% stiffer than the original one, 10% lighter, and economically competitive.

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Manufacturing of thin wall structures in AlSi10Mg alloy by laser powder bed fusion through process parameters

Cited by 61 publications

References 31 publications

Effect of the Process Gas and Scan Speed on the Properties and Productivity of Thin 316L Structures Produced by Laser-Powder Bed Fusion

Effect of the Process Gas and Scan Speed on the Properties and Productivity of Thin 316L Structures Produced by Laser-Powder Bed Fusion

A Metal Powder Bed Fusion Process in Industry: Qualification Considerations

Additive Manufacturing Redesigning of Metallic Parts for High Precision Machines

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