Physics of large-area pulsed laser powder bed fusion

Roehling, John D.; Khairallah, Saad A.; Shen, Yiou; Bayramian, Andrew James; Boley, C. D.; Rubenchik, Alexander M.; DeMuth, James; Duanmu, Ning; Matthews, Manyalibo J.

doi:10.1016/j.addma.2021.102186

Cited by 9 publications

(6 citation statements)

References 23 publications

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“…To date, the main means to increase the throughput of LPBF equipment is to increase the number of independently scanned lasers within the machine, which incurs additional capital cost from the lasers and the required scanning optics and control hardware for each laser, and for coordination of the laser scanning overall. An alternative approach, among others that may emerge, is to provide a single laser beam with much higher power than each laser in the current LPBF machine architecture, and to expose a relatively large area of the powder bed via spatial modulation of the single beam, such as proposed in Roehling et al (2021). Ultimately, to gain increased market share, these machines will be reliant upon reducing the capital cost per unit of laser power (i.e.…”

Section: Resultsmentioning

confidence: 99%

A physics-based modeling framework to assess the cost scaling of additive manufacturing, with application to laser powder bed fusion

Gee

Kim

Quinlan

et al. 2022

RPJ

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Purpose This study presents a framework to estimate throughput and cost of additive manufacturing (AM) as related to process parameters, material thermodynamic properties and machine specifications. Taking a 3D model of the part design as input, the model uses a parametrization of the rate-limiting physics of the AM build process – herein focusing on laser powder bed fusion (LPBF) and scaling of LPBF melt pool geometry – to estimate part- and material-specific build time. From this estimate, per-part cost is calculated using a quantity-dependent activity-based production model. Design/methodology/approach Analysis tools that assess how design variables and process parameters influence production cost increase our understanding of the economics of AM, thereby supporting its practical adoption. To this aim, our framework produces a representative scaling among process parameters, build rate and production cost. Findings For exemplary alloys and LPBF system specifications, predictions reveal the underlying tradeoff between production cost and machine capability, and look beyond the capability of currently commercially available equipment. As a proxy for build quality, the number of times each point in the build is re-melted is derived analytically as a function of process parameters, showcasing the tradeoff between print quality due to increased melting cycles, and throughput. Originality/value Typical cost models for AM only assess single operating points and are not coupled to models of the representative rate-limiting process physics. The present analysis of LPBF elucidates this important coupling, revealing tradeoffs between equipment capability and production cost, and looking beyond the limits of current commercially available equipment.

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Section: Resultsmentioning

confidence: 99%

A physics-based modeling framework to assess the cost scaling of additive manufacturing, with application to laser powder bed fusion

Gee

Kim

Quinlan

et al. 2022

RPJ

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“…The build platform moves down as the layer is finished, and the roller spreads more powder from a supply chamber to prepare next layer. [82,83] This process must be done inside a chamber with inert atmosphere to avoid the oxidative degradation of the material. [84] Laser sintering (LS), Laser Melting (LM), and Electron Beam Melting (EBM) are some of the widely used PBF processes.…”

Section: Powder Bed Fusionmentioning

confidence: 99%

“…[103] Nevertheless, EBM has some disadvantages such as the need to operate in a vacuum to prevent air-electron interaction, the powder should be electrically conductive leading to fewer material options in comparison to LS and LM, and the coarse powder need to be pre-sintered. [82,104] These factors lead to rougher surfaces and generally larger minimum feature size compared to laser processing. Besides, it is important to mention that the necessity of removing the non-melted powder may limit the monolithic geometric design and cell density, making it disadvantageous regarding other AM techniques.…”

Section: Electron Beam Meltingmentioning

confidence: 99%

Revolutionizing Monolithic Catalysts: The Breakthroughs of Design Control through Computer‐Aided‐Manufacturing

Parra‐Marfil,

Pérez‐Cadenas,

Carrasco‐Marín

et al. 2024

Adv Materials Technologies

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Additive manufacturing (AM) presents a promising opportunity for the innovative design and production of structured catalytic materials. Given the critical role of catalysts in industrial catalytic processes, AM has the potential to contribute to the development of improved catalysts by reducing activation energy and enhancing selectivity. Conventional synthesis methods limit the choice of structural materials and composition for producing monoliths. Additionally, the deposition of catalytic compounds is also restricted by commonly applied techniques that may require prior coverage or treatments to improve adherence or do not achieve a homogenous coat. Moreover, production is limited to monoliths with straight and parallel channels. However, this format drives to laminar regime flow thus restricting the radial mass and heat transfer. Conversely, AM allows the production of a wider variety of compositions and more complex structures that have proven to rise their effectiveness by increasing reagents‐catalyst interaction, making catalytic processes more cost‐effective. Therefore, in this review an outline of the recent progress of AM methods in the development of monolithic catalysts is presented focusing on the requirements, advantages, and disadvantages of each technique, hence providing a practical overview of their novel opportunities to overcome current limitations in catalyst synthesis.

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“…Benefits of L-APBF include lower residual stress and less material ejection compared to conventional LPBF. However, more research is needed to determine the benefits and drawbacks of the method [ 24 ]. Figure 2 d shows the schematics of an L-APBF system.…”

Section: Multimetal Additive Manufacturing Techniquesmentioning

confidence: 99%

Multimetal Research in Powder Bed Fusion: A Review

et al. 2023

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This article discusses the different forms of powder bed fusion (PBF) techniques, namely laser powder bed fusion (LPBF), electron beam powder bed fusion (EB-PBF) and large-area pulsed laser powder bed fusion (L-APBF). The challenges faced in multimetal additive manufacturing, including material compatibility, porosity, cracks, loss of alloying elements and oxide inclusions, have been extensively discussed. Solutions proposed to overcome these challenges include the optimization of printing parameters, the use of support structures, and post-processing techniques. Future research on metal composites, functionally graded materials, multi-alloy structures and materials with tailored properties are needed to address these challenges and improve the quality and reliability of the final product. The advancement of multimetal additive manufacturing can offer significant benefits for various industries.

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Physics of large-area pulsed laser powder bed fusion

Cited by 9 publications

References 23 publications

A physics-based modeling framework to assess the cost scaling of additive manufacturing, with application to laser powder bed fusion

A physics-based modeling framework to assess the cost scaling of additive manufacturing, with application to laser powder bed fusion

Revolutionizing Monolithic Catalysts: The Breakthroughs of Design Control through Computer‐Aided‐Manufacturing

Multimetal Research in Powder Bed Fusion: A Review

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