Predictive Simulation of Process Windows for Powder Bed Fusion Additive Manufacturing: Influence of the Powder Bulk Density

Rausch, Alexander M.; Küng, Vera E.; Pobel, Christoph R.; Markl, Matthias; Körner, Carolin

doi:10.3390/ma10101117

Cited by 79 publications

(37 citation statements)

References 39 publications

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“…The optimization of the process parameters brings about manufacturing of high-quality products by PBF process (Qui et al, 2015;Rausch et al, 2017). The optimum fabrication condition is generally found out by the following steps:…”

Section: E=p/vht (5)mentioning

confidence: 99%

A review of metal additive manufacturing technologies: Mechanism of defects formation and simulation of melting and solidification phenomena in laser powder bed fusion process

Kyogoku

Ikeshoji

2020

Mechanical Engineering Reviews

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In this review, the analysis of melting and solidification phenomena and the mechanism of the occurrence of defects as well as the analysis of melting and solidification using the numerical simulation in laser powder bed fusion (LPBF) process were introduced. In addition, the strategies of suppression of defects were described. The melting and solidification phenomena during LPBF process are relatively similar to those during welding.Since the plume brings about the strong recoil pressure on the melt pool, the keyhole takes place. And when the depth of keyhole becomes more than a threshold, the keyhole pore remains at the bottom of melt pool. Since the plume also brings about spattering and blows out powder, the gas pores are prone to occur easily. The micro-simulation of melting and solidification enables to reproduce the real phenomena. The macro-simulation of melting and solidification phenomena is one of the effective tools to predict the optimum fabrication condition. In order to prevent the occurrence of defects, it is significant not only to obtain the optimum fabrication condition using the process map but also to develop the simulation software. In addition, the use of the monitoring and feedback control system is greatly effective. Therefore the development of the cyber-physical system is needed.

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Section: E=p/vht (5)mentioning

confidence: 99%

A review of metal additive manufacturing technologies: Mechanism of defects formation and simulation of melting and solidification phenomena in laser powder bed fusion process

Kyogoku

Ikeshoji

2020

Mechanical Engineering Reviews

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“…The reasons for the formation of such channels were identified and demonstrated with the software. [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.…”

Section: Powder Bed Effectsmentioning

confidence: 99%

“…[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%

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

et al. 2019

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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.

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“…Similarly, Branco et al studied the cyclic plastic behavior of the 18Ni300 maraging steel processed by LPBF, and observed cracks initiated from the surface and inner defects which propagated through the rest of the cross section [12]. Rausch et al used numerical simulation to examine the influence of the stochastic powder bed on the process window for dense parts-an increase in the porosity and the surface roughness for samples produced with lower powder bulk densities was observed [13]. Read et al applied statistical design of experiments to study the influence of process parameters on the porosity development in an AlSi10Mg alloy, and a two-factor interaction model showed that the laser power, scanning speed, and the interaction between the scanning speed and scan spacing have the major influence on the porosity development in the built components [14].…”

Section: Introductionmentioning

confidence: 99%

Characterization of 17-4PH Single Tracks Produced at Different Parametric Conditions towards Increased Productivity of LPBF Systems—The Effect of Laser Power and Spot Size Upscaling

Makoana

Yadroitsava

Möller

et al. 2018

Metals

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Global industrial adoption of laser-based powder bed fusion (LPBF) technology is still limited by the production speed, the size of the build envelope, and therefore the maximum part size that can be produced. The cost of LPBF can be driven down further by improving the build rates without compromising structural integrity. A common approach is that the build rate can be improved by increasing the laser power and beam diameter to instantly melt a large area of powder, thus reducing the scanning time for each layer. The aim of this study was to investigate the aspects of upscaling LPBF processing parameters on the characteristic formation of stable single tracks, which are the primary building blocks for this technology. Two LPBF systems operating independently, using different parameter regimes, were used to produce the single tracks on a solid substrate deposited with a thin powder layer. The results obtained indicate that higher laser power and spot size can be used to produce stable tracks while the linear energy input is increased. It was also shown statistically that the geometrical characteristics of single tracks are mainly affected by the laser power and scanning speed during the scanning of a thin powder layer.

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Predictive Simulation of Process Windows for Powder Bed Fusion Additive Manufacturing: Influence of the Powder Bulk Density

Cited by 79 publications

References 39 publications

A review of metal additive manufacturing technologies: Mechanism of defects formation and simulation of melting and solidification phenomena in laser powder bed fusion process

A review of metal additive manufacturing technologies: Mechanism of defects formation and simulation of melting and solidification phenomena in laser powder bed fusion process

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

Characterization of 17-4PH Single Tracks Produced at Different Parametric Conditions towards Increased Productivity of LPBF Systems—The Effect of Laser Power and Spot Size Upscaling

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