On the feasibility of AISI 304 stainless steel laser welding with metal powder

Errico, Vito; Campanelli, Sabina Luisa; Angelastro, Andrea; Mazzarisi, Marco; Casalino, Giuseppe

doi:10.1016/j.jmapro.2020.04.065

Cited by 28 publications

(15 citation statements)

References 35 publications

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“…Eventually, the weld profile will approach a typical CW weld profile with a further increase of t i . However, this model is not necessarily a good theory, especially for the same penetration depth due to fit-up problems [5]. Similar trend lines observed in PW micro-seam welding in Fig.…”

Section: Effect Of Pulse Power Factor and Interaction Time For Pw Weldingsupporting

confidence: 66%

“…Nevertheless, it is necessary to have a very accurate positioning [3,4]. For a butt-joint configuration, for instance, the presence of a gap between the base materials is critical, being important to avoid that the beam passes through without interacting with the joining partners [5]. Therefore, a robust experimental setup is necessary to ensure repetitive and reliable results [6].…”

Section: Introductionmentioning

confidence: 99%

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Selection of parameters in nanosecond pulsed wave laser micro-welding

Coroado

Ganguly

Suder

et al. 2021

Int J Adv Manuf Technol

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The digital control of the latest nanosecond pulsed wave (PW) fibre lasers allows very high flexibility in controlling the application of the total energy to a workpiece, which brings several advantages to the joining process. By choosing different pulse shapes in different spatial profiles, it is possible to apply low energy per pulse with high precision and accuracy resulting in lower heat input. Since the energy of each pulse is insufficient to generate melting, these lasers operate at very high pulse repetition frequencies near continuous wave (CW) regime. Nevertheless, the peak powers of PW lasers are much higher than CW. In this research, the effect of peak power, pulse energy, pulse width, pulse repetition frequency and duty cycle has been studied. The experimental work was conducted in bead on plate of austenitic stainless steel to investigate the effect of laser on the weld geometry, i.e. depth of penetration and width. An empirical model, previously established for CW mode, which enables the achievement of a particular penetration depth independent of the beam diameter, was redesigned and tested for PW mode. The “pulse power factor model” allows the laser user to select a weld profile that meets certain quality and productivity requirements independent of the laser system. It was shown that identical depth of penetration but different weld metal profile can be obtained for a specific beam diameter for a range of different system parameters by keeping a constant trade-off between pulse power factor and interaction time.

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Section: Effect Of Pulse Power Factor and Interaction Time For Pw Weldingsupporting

confidence: 66%

Section: Introductionmentioning

confidence: 99%

Selection of parameters in nanosecond pulsed wave laser micro-welding

Coroado

Ganguly

Suder

et al. 2021

Int J Adv Manuf Technol

View full text Add to dashboard Cite

show abstract

“…As mentioned above, thin-wall depositions were performed with the same process parameters that were obtained from prior studies and evaluated as appropriate for multilayer depositions. The process parameters that were kept constant based on previous tests [ 27 ] are listed in Table 4 .…”

Section: Methodsmentioning

confidence: 99%

Coaxial Monitoring of AISI 316L Thin Walls Fabricated by Direct Metal Laser Deposition

et al. 2021

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Direct metal laser deposition (DMLD) is an additive manufacturing technique suitable for coating and repair, which has been gaining a growing interest in 3D manufacturing applications in recent years. However, its diffusion in the manufacturing industry is still limited due to technical challenges to be solved—both the sub-optimal quality of the final parts and the low repeatability of the process make the DMLD inadequate for high-value applications requiring high-performance standards. Thus, real-time monitoring and process control are indispensable requirements for improving the DMLD process. The aim of this study was the optimization of deposition strategies for the fabrication of thin walls in AISI 316L stainless steel. For this purpose, a coaxial monitoring system and image processing algorithms were employed to study the melt pool geometry. The comparison tests carried out highlighted how the region-based active contour algorithm used for image processing is more efficient and stable than others covered in the literature. The results allowed the identification of the best deposition strategy. Therefore, it is shown how this monitoring methodology proved to be suitable for designing and implementing the right building strategy for DMLD manufactured 3D components. A fast and stable image processing method was achieved, which can be considered for future closed-loop monitoring in real-time applications.

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“…This allowed a gradually increase in input power to provide a constant output power. The laser deposition is a process that usually operates in conduction mode requiring lower powers than laser welding, in which very high energy densities are necessary to work in keyhole mode and instantly vaporize the material [67]. The 4-kW laser source mounted in the DLMD system is then used with powers close to the lowest limit available for stable processing, equal to 10% of the nominal power.…”

Section: Electrical Energy and Temperature Acquisition Testmentioning

confidence: 99%

A monitoring framework based on exergetic analysis for sustainability assessment of direct laser metal deposition process

Selicati

Mazzarisi

Lovecchio

et al. 2021

Int J Adv Manuf Technol

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With the constant increase of energy costs and environmental impacts, improving the process efficiency is considered a priority issue for the manufacturing field. A wide knowledge about materials, energy, machinery, and auxiliary equipment is required in order to optimize the overall performance of manufacturing processes. Sustainability needs to be assessed in order to find an optimal compromise between technical quality of products and environmental compatibility of processes. In this new Industry 4.0 era, innovative manufacturing technologies, as the additive manufacturing, are taking a predominant role. The aim of this work is to give an insight into how thermodynamic laws contribute at the same time to improve energy efficiency of manufacturing resources and to provide a methodological support to move towards a smart and sustainable additive process. In this context, a fundamental step is the proper design of a sensing and real-time monitoring framework of an additive manufacturing process. This framework should be based on an accurate modelling of the physical phenomena and technological aspects of the considered process, taking into account all the sustainability requirements. To this end, a thermodynamic model for the direct laser metal deposition (DLMD) process was proposed as a test case. Finally, an exergetic analysis was conducted on a prototype DLMD system to validate the effectiveness of an ad-hoc monitoring system and highlight the limitations of this process. What emerged is that the proposed framework provided significant advantages, since it represents a valuable approach for finding suitable process management strategies to identify sustainable solutions for innovative manufacturing procedures.

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On the feasibility of AISI 304 stainless steel laser welding with metal powder

Cited by 28 publications

References 35 publications

Selection of parameters in nanosecond pulsed wave laser micro-welding

Selection of parameters in nanosecond pulsed wave laser micro-welding

Coaxial Monitoring of AISI 316L Thin Walls Fabricated by Direct Metal Laser Deposition

A monitoring framework based on exergetic analysis for sustainability assessment of direct laser metal deposition process

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