Metal-Based 3D-Printed Micro Parts &amp; Structures

Xu, Song; Zhai, Wei; Huang, Rui; Fu, Jin; Fu, Mingwang; Feng, Li

doi:10.1016/b978-0-12-819726-4.00009-0

Cited by 18 publications

(8 citation statements)

References 28 publications

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“…In the powder-bed fusion process, a thin layer (typically 20-100 µm) of very fine powder (with particle size in the range of 20-50 µm) [50] is spread closely packed on a platform. This is where the powder is then fused together with a laser beam or an electron beam.…”

Section: Powder-bed Fusionmentioning

confidence: 99%

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Ozden

Morley

2021

Magnetochemistry

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Fe-based amorphous materials offer new opportunities for magnetic sensors, actuators, and magnetostrictive transducers due to their high saturation magnetostriction (λs = 20–40 ppm) and low coercive field compared with polycrystalline Fe-based alloys, which have high magnetostriction but large coercive fields and Co-based amorphous alloys with small magnetostriction (λs = −3 to −5 ppm). Additive layer manufacturing (ALM) offers a new fabrication technique for more complex net-shaping designs. This paper reviews the two different ALM techniques that have been used to fabricate Fe-based amorphous magnetic materials, including the structural and magnetic properties. Selective laser melting (SLM)—a powder-bed fusion technique—and laser-engineered net shaping (LENS)—a directed energy deposition method—have both been utilised to fabricate amorphous alloys, owing to their high availability and low cost within the literature. Two different scanning strategies have been introduced by using the SLM technique. The first strategy is a double-scanning strategy, which gives rise to maximum relative density of 96% and corresponding magnetic saturation of 1.22 T. It also improved the glassy phase content by an order of magnitude of 47%, as well as improving magnetic properties (decreasing coercivity to 1591.5 A/m and increasing magnetic permeability to around 100 at 100 Hz). The second is a novel scanning strategy, which involves two-step melting: preliminary laser melting and short pulse amorphisation. This increased the amorphous phase fraction to a value of up to 89.6%, and relative density up to 94.1%, and lowered coercivity to 238 A/m. On the other hand, the LENS technique has not been utilised as much as SLM in the production of amorphous alloys owing to its lower geometric accuracy (0.25 mm) and lower surface quality, despite its benefits such as providing superior mechanical properties, controlled composition and microstructure. As a result, it has been commonly used for large parts with low complexity and for repairing them, limiting the production of amorphous alloys because of the size limitation. This paper provides a comprehensive review of these techniques for Fe-based amorphous magnetic materials.

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Section: Powder-bed Fusionmentioning

confidence: 99%

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Ozden

Morley

2021

Magnetochemistry

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“…After completing the scan of one layer, the substrate moves down by a certain distance equal to the layer thickness and a new layer of powder is deposited. The layer-by-layer process repeats until the samples are completed [54]. The build length of the EOS M 400 machine is 400 mm [55].…”

Section: Cost Modelingmentioning

confidence: 99%

Mathematical Modeling of Multi-Performance Metrics and Process Parameter Optimization in Laser Powder Bed Fusion

Abdulla

Barsoum

et al. 2022

Metals

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This study aims to develop mathematical models to improve multi-performance metrics, such as relative density and operating costs, in laser powder bed fusion (LPBF), also known as selective laser melting, a metallic additive manufacturing technique, by optimizing the printing process parameters. The work develops a data-driven model for relative density based on measurements and an analytical model for operating costs related to the process parameters. Optimization models are formulated to maximize relative density or minimize operating costs by determining the optimal set of process parameters, while meeting a target level of the other performance metrics (i.e., relative density or operating costs). Furthermore, new metrics are devised to test the sensitivity of the optimization solutions, which are used in a novel robust optimization model to acquire less sensitive process parameters. The sensitivity analysis examines the effect of varying some parameters on the relative density of the fabricated specimens. Samples with a relative density greater than 99% and a machine operating cost of USD 1.00 per sample can be produced, utilizing a combination of low laser power (100 W), high scan speed (444 mm/s), moderate layer thickness (0.11 mm), and large hatch distance (0.4 mm). This is the first work to investigate the relationship between the quality of the fabricated samples and operating cost in the LPBF process. The formulated robust optimization model achieved less sensitive parameter values that may be more suitable for real operations. The equations used in the models are verified via 10-fold cross-validation, and the predicted results are further verified by comparing them with the experimental data in the literature. The multi-performance optimization models and framework presented in this study can pave the way for other additive manufacturing techniques and material grades for successful industrial-level implementation.

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“…SLM 3D-printable Al-Si-Mg alloy has been recently utilized for the fabrication of thermoregulation casing of a gamma-ray detectors used in satellite applications [7]. Heatingcooling cycles are typical for many outer-space structures and devices forming parts of satellite equipment that alternatively pass lit and shadowed zones.…”

Section: Introductionmentioning

confidence: 99%

Comparative Multi-Modal, Multi-Scale Residual Stress Evaluation in SLM 3D-Printed Al-Si-Mg Alloy (RS-300) Parts

Statnik

Uzun

Lipovskikh

et al. 2021

Metals

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SLM additive manufacturing has demonstrated great potential for aerospace applications when structural elements of individual design and/or complex shape need to be promptly supplied. 3D-printable AlSi10Mg (RS-300) alloy is widely used for the fabrication of different structures in the aerospace industry. The importance of the evaluation of residual stresses that arise as a result of the 3D-printing process’ complex thermal history is widely discussed in literature, but systematic assessment remains lacking for their magnitude, spatial distribution, and comparative analysis of different evaluation techniques. In this study, we report the results of a systematic study of residual stresses in 3D-printed double tower shaped samples using several approaches: the contour method, blind hole drilling laser speckle interferometry, X-ray diffraction, and Xe pFIB-DIC micro-ring-core milling analysis. We show that a high level of tensile and compressive residual stresses is inherited from SLM 3D-printing and retained for longer than 6 months. The stresses vary (from −80 to +180 MPa) over a significant proportion of the material yield stress (from −⅓ to ¾). All residual stress evaluation techniques considered returned comparable values of residual stresses, regardless of dramatically different dimensional scales, which ranged from millimeters for the contour method, laser speckle interferometry, and XRD down to small fractions of a mm (70 μm) for Xe pFIB-DIC ring-core drilling. The use of residual stress evaluation is discussed in the context of optimizing printing strategies to enhance mechanical performance and long-term durability.

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Metal-Based 3D-Printed Micro Parts & Structures

Cited by 18 publications

References 28 publications

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Laser Additive Manufacturing of Fe-Based Magnetic Amorphous Alloys

Mathematical Modeling of Multi-Performance Metrics and Process Parameter Optimization in Laser Powder Bed Fusion

Comparative Multi-Modal, Multi-Scale Residual Stress Evaluation in SLM 3D-Printed Al-Si-Mg Alloy (RS-300) Parts

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