Predictive simulation of process windows for powder bed fusion additive manufacturing: Influence of the powder size distribution

Rausch, Alexander M.; Markl, Matthias; Körner, Carolin

doi:10.1016/j.camwa.2018.06.029

Cited by 36 publications

(23 citation statements)

References 28 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The laser interacts with a discrete substrate formed by metal powder particles that are used as feedstock; these are micron-sized particles of the selected alloy, obtained using specific processes. It is necessary for L-PBF to flow easily during the recoating phase to guarantee a proper powder bed density; various studies [94][95][96][97] demonstrated the impact of different particles characteristics on the quality (in particular, in terms of density and surface roughness) of the final component. The majority of metal powders used in L-PBF systems are, nowadays, produced through an atomizing process that involves the interaction of a stream of molten metal with a high energy jet, usually gaseous (e.g., nitrogen of argon) [98]; this process is called gas atomization (GA).…”

Section: Laser Powder Bed Fusion Working Principles and Process-relatmentioning

confidence: 99%

Laser Powder Bed Fusion of Stainless Steel Grades: A Review

Zitelli¹,

Folgarait²,

Schino

2019

Metals

View full text Add to dashboard Cite

In this paper, the capability of laser powder bed fusion (L-PBF) systems to process stainless steel alloys is reviewed. Several classes of stainless steels are analyzed (i.e., austenitic, martensitic, precipitation hardening and duplex), showing the possibility of satisfactorily processing this class of materials and suggesting an enlargement of the list of alloys that can be manufactured, targeting different applications. In particular, it is reported that stainless steel alloys can be satisfactorily processed, and their mechanical performances allow them to be put into service. Porosities inside manufactured components are extremely low, and are comparable to conventionally processed materials. Mechanical performances are even higher than standard requirements. Micro surface roughness typical of the as-built material can act as a crack initiator, reducing the strength in both quasi-static and dynamic conditions.

show abstract

Section: Laser Powder Bed Fusion Working Principles and Process-relatmentioning

confidence: 99%

Laser Powder Bed Fusion of Stainless Steel Grades: A Review

Zitelli¹,

Folgarait²,

Schino

2019

Metals

View full text Add to dashboard Cite

show abstract

“…Here three aspects related to as-manufactured state of the PB-AM components should be kept in mind: component surface roughness; different thermal history of the different parts of the component; possible residual stress in the material and presence of the supports. Because molten metal in PB-AM is directly neighboring loose or slightly sintered powder, component outer surfaces will have certain roughness, with average values commonly determined by the dimensions of the used powder grains, partially fused with the outer surfaces [41,42].…”

Section: Powder-bed Additive Manufacturingmentioning

confidence: 99%

Powder-bed additive manufacturing for aerospace application: Techniques, metallic and metal/ceramic composite materials and trends

et al. 2019

View full text Add to dashboard Cite

The current paper is devoted to classification of powder-bed additive manufacturing (PB-AM) techniques and description of specific features, advantages and limitation of different PB-AM techniques in aerospace applications. The common principle of “powder-bed” means that the used feedstock material is a powder, which forms “bed-like” platform of homogeneous layer that is fused according to cross-section of the manufactured object. After that, a new powder layer is distributed with the same thickness and the “printing” process continues. This approach is used in selective laser sintering/melting process, electron beam melting, and binder jetting printing. Additionally, relevant issues related to powder raw materials (metals, ceramics, multi-material composites, etc.) and their impact on the properties of as-manufactured components are discussed. Special attention is paid to discussion on additive manufacturing (AM) of aerospace critical parts made of Titanium alloys, Nickel-based superalloys, metal matrix composites (MMCs), ceramic matrix composites (CMCs) and high entropy alloys. Additional discussion is related to the quality control of the PB-AM materials, and to the prospects of new approaches in material development for PB-AM aiming at aerospace applications.

show abstract

“…[31] After a successful validation, in comparison with experiments, [41] the software was applied to predicting further process windows with modified process conditions. Thus, the influence of the powder bulk density [41] and powder size distribution [27] were altered to increase the process window. One key factor in the simulations is that it is possible to isolate different properties, such as powder bulk density and powder size distribution, which are naturally related, and study how, and to what extent, they influence the process.…”

Section: Powder Bed Effectsmentioning

confidence: 99%

“…Similarly, the powder size distribution was varied for a constant powder bulk density. [27] With a decreasing mean particle diameter, the probability of binding faults decreases. The effect on process windows is comparable with the increase in powder bulk density.…”

Section: Powder Bed Effectsmentioning

confidence: 99%

S𝔸𝕄PLE: A Software Suite to Predict Consolidation and Microstructure for Powder Bed Fusion Additive Manufacturing

et al. 2019

Self Cite

View full text Add to dashboard Cite

Powder bed fusion comprises all layer‐by‐layer additive manufacturing technologies of parts built from a powder bed. To exploit the advantages of near‐net shape manufacturing of complex geometries, in contrast to conventional manufacturing techniques, it is essential to understand the underlying physical phenomena occurring during processing for a broad range of different process scenarios. Experimental approaches are costly in time and material and provide only limited access inside the process. However, to understand the process behavior and predict final properties of parts, numerical approaches are powerful tools. This work presents the software suite S𝔸𝕄PLE (Simulation of Additive Manufacturing on the Powder scale using a Laser or Electron beam) which simulates the consolidation and microstructure evolution during beam‐based powder bed fusion processes. It is based on a mesoscopic approach, in which statistical powder beds, melt pool dynamics, evaporation effects, and microstructure evolution are considered and can simulate the build‐up of more than 100 layers. The underlying models and algorithms of the software including a newly applied thermal model are described. Finally, the unique potential of the software is demonstrated by reviewing the influence of various powder bed properties, the effects of evaporation, and the grain structure evolution in the process.

show abstract

Predictive simulation of process windows for powder bed fusion additive manufacturing: Influence of the powder size distribution

Cited by 36 publications

References 28 publications

Laser Powder Bed Fusion of Stainless Steel Grades: A Review

Laser Powder Bed Fusion of Stainless Steel Grades: A Review

Powder-bed additive manufacturing for aerospace application: Techniques, metallic and metal/ceramic composite materials and trends

S𝔸𝕄PLE: A Software Suite to Predict Consolidation and Microstructure for Powder Bed Fusion Additive Manufacturing

Contact Info

Product

Resources

About