Optimization on selective laser sintering of metallic powder via design of experiments method

Abstract

Purpose -The objective of this study is to investigate the effect of various parameters on rapid prototyping parts for processes of sintering metallic powder by using Nd:YAG laser via the design of experiments (DOE) method. Design/methodology/approach -Experiments based on the DOE method were utilized to determine an optimal parameter setting for achieving a minimum amount of porosities in specimens during the selective laser sintering (SLS) process. Analysis of variance (ANOVA) was further conducted to identify significant factors. Findings -A regression model predicting percentages of porosities under various conditions was developed when the traditional Taguchi's approach failed to identify a feasible model due to strong interactions of controlled factors. The significant factors to the process were identified by ANOVA.Research limitations/implications -Four controlled factors including pulse frequencies and pulse durations of laser beams, times of strikes of a pulse applying on a single laser spot and particle sizes of the powder base material had significant influence on the sintering process. Future investigation planned to be carried out for achieving multiple quality targets such as the hardness and the density for 3D parts. Originality/value -The implementation of the DOE method provided a systematic approach to identify an optimal parameter setting of the SLS process; thus, the efficiency of designing optimal parameters was greatly improved. This approach could be easily extended to 3D cases by just including additional parameters into the design. Additionally, utilization of the normality analysis on the residual data ensured that the selected model was adequate and extracted all applicable information from the experimental data.

Behaviour Investigation of Plastic Parts Made from Selective Laser Sintering

“…The methodology is based on design of experiments [4] (DE) under two different scenarios: (1) considering 3DSystem and EOS technologies separately, (2) ana-lysing the two technologies into DE approach. Statistic calculation with ANOVA table was applied in both cases, showing the effects of different factors o n the variables (five factors and five variables).…”

Refining the Microstructure of Fe‐Nd‐B by Selective Laser Melting

“…Recently, it has been demonstrated that fine‐tuning the laser parameters may result in stabilization of the intended Fe 14 Nd 2 B phase with reduced (but still present) iron segregation for high cooling rates and the MQP‐S powder used . In general, microstructure and related properties of 3D printed (SLM) components are mainly influenced by processing parameters (laser power, laser scan velocity, laser scan grid space, substrate conditions, thickness of powder layer) and powder characteristics (particle shape, rheology, particle size, inner porosity, purity, humidity) …”

“…[5] In general, microstructure and related properties of 3D printed (SLM) components are mainly influenced by processing parameters (laser power, laser scan velocity, laser scan grid space, substrate conditions, thickness of powder layer) and powder characteristics (particle shape, rheology, particle size, inner porosity, purity, humidity). [8,9] In this paper, the feasibility of SLM using oxidation-sensitive permanent magnet Fe-Nd-B powder is demonstrated. In contrast to existing industrial methods for improving the grain size of Fe-Nd-B based sintered magnets, [10] the aim is to investigate a fundamental research approach.…”

Process parameters investigation of a laser-generated single clad for minimum size using design of experiments

“…Response surface method is used to find out possible linear or non-linear relations between parameter levels and results generating regression analysis (Montgomery, 1997). Design of experiments (DOE) methods and some statistical analysis techniques were commonly used to achieve optimum solution at some various targets as in Miller et al (1997), Davim et al (2008), Song et al (2005), Yang et al (2002), Tarng and Yang (1998), Pan et al (2004), Liao and Shie (2007), Onwubolu et al (2007) and Chen et al (1996).…”