Process planning guidelines in selective laser melting for the manufacturing of stainless steel parts

Ramírez-Cedillo, Erick; Sandoval-Robles, Jesús A.; Ruiz‐Huerta, Leopoldo; Caballero-Ruiz, Alberto; Rodríguez, Ciro A.; Siller, Héctor R.

doi:10.1016/j.promfg.2018.07.125

Cited by 17 publications

(4 citation statements)

References 23 publications

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“…The LPBF fabrication was conducted in a Renishaw AM400 machine equipped with a ytterbium fiber laser with 400 W of maximum power. The processing parameters, based on a previously published work [ 30 ], are shown in Table 2 . The cylindrical samples were printed vertically, with the z-axis in Figure 1 and Figure 2 normal to the printing bed.…”

Section: Methodsmentioning

confidence: 99%

Mechanical Properties of AISI 316L Lattice Structures via Laser Powder Bed Fusion as a Function of Unit Cell Features

et al. 2023

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The growth of additive manufacturing processes has enabled the production of complex and smart structures. These fabrication techniques have led research efforts to focus on the application of cellular materials, which are known for their thermal and mechanical benefits. Herein, we studied the mechanical behavior of stainless-steel (AISI 316L) lattice structures both experimentally and computationally. The lattice architectures were body-centered cubic, hexagonal vertex centroid, and tetrahedron in two cell sizes and at two different rotation angles. A preliminary computational study assessed the deformation behavior of porous cylindrical samples under compression. After the simulation results, selected samples were manufactured via laser powder bed fusion. The results showed the effects of the pore architecture, unit cell size, and orientation on the reduction in the mechanical properties. The relative densities between 23% and 69% showed a decrease in the bulk material stiffness up to 93%. Furthermore, the different rotation angles resulted in a similar porosity level but different stiffnesses. The simulation analysis and experimental results indicate that the variation in the strut position with respect to the force affected the deformation mechanism. The tetrahedron unit cell showed the smallest variation in the elastic modulus and off-axis displacements due to the cell orientation. This study collected computational and experimental data for tuning the mechanical properties of lattice structures by changing the geometry, size, and orientation of the unit cell.

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Section: Methodsmentioning

confidence: 99%

Mechanical Properties of AISI 316L Lattice Structures via Laser Powder Bed Fusion as a Function of Unit Cell Features

et al. 2023

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“…Considering the angle between the longitudinal axis of the specimens and the building plate three replicates were manufactured in a horizontal (0°) and vertical (90°) orientation. The selected parameters and scanning strategy were selected based on the previous work of Ramirez et al [23] for wall width tests and lattice structures (Table 2). The layer thickness was reduced from 50 µm down to 40 µm compared to our previous work.…”

Section: Methodsmentioning

confidence: 99%

A dimensional assessment of small features and lattice structures manufactured by laser powder bed fusion

et al. 2022

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The understanding of dimensional variations produced by laser powder bed fusion is critical in components with small features and with dimensions close to the inherent limits of the process. In this context, two reference geometries were used: (a) straight walls to quantify dimensional relative error for small features and (b) a latticed neck region of a fatigued specimen (cubic and hexagonal cell design, with design strut sizes of 250 µm, 500 µm, and 1000 µm in cell size). Samples were fabricated out of AISI 316L stainless steel powder with different building orientations. The metrology techniques used were the following: focus variation microscopy, optical microscopy and micro-computed tomography. The straight wall characterization shows that built orientation does not influence dimensional relative error for walls with less than 750 µm. Acceptable dimensional relative errors (~ 2% to ~ 15%) are achieved only in walls with 750 µm in width of more. For lattice structures, the fine struts (250 µm) show a significant level of dimensional relative error (~ 5% to ~ 25%). This additive manufacturing process delivers more consistent dimensions for coarse struts (500 µm), with relative errors between ~ 2% and ~ 4%. All metrology techniques showed the same trends in terms of capturing the dimensional variations for fine and coarse struts.

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“…The feasibility of the dry cut turning was demonstrated for a carbide coated tip with a zero rake angle over a small length of 0.17 mm, and although the surface roughness increased slightly, the tool life was within reasonable bounds. Other published works [ 8 , 12 , 13 , 14 , 15 ] covering milling and turning of the IN718 alloy, comparing dry cut, conventional coolant systems, cryogenic and the minimum quantity lubricant (MQL) had sought to determine the productivity improvement for roughing and finishing.…”

Section: Introductionmentioning

confidence: 99%

“…Studies have been published [ 30 ] to establish the optimum combination of process parameters for LM-PBF metals and alloys such as 316 L, Ti-6Al-4 V, and AlSi10 Mg, seeking to minimize process defects and surface roughness, improve alloy integrity, and increase process productivity. More recently, the IN718 alloy has received increased interest [ 13 , 28 , 31 , 33 ]. Despite the capabilities of the LM-PBF and the refinements reported, it can only be considered a near net shape manufacturing process for high precision components.…”

Section: Introductionmentioning

confidence: 99%

Machinability of INCONEL718 Alloy with a Porous Microstructure Produced by Laser Melting Powder Bed Fusion at Higher Energy Densities

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Díaz-Álvarez

et al. 2020

Materials

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Products produced by additive manufacturing (AM) seek to exploit net shape manufacturing by eliminating or minimizing post-process stages such as machining. However, many applications which include turbo machinery components with tight dimensional tolerances and a smooth surface finish will require at least a light machine finishing stage. This paper investigates the machinability of the additively fabricated INCONEL718 (IN718) alloy produced by laser melting powder bed fusion (LM-PBF) with different levels of spherical porosity in the microstructure. The literature suggests that the band width for laser energy density, which combines the various scan process parameters to obtain a low spherical type porosity in the LM-PBF IN718 alloy (~1%), has wide breadth. With the increasing laser energy density and above a threshold, there is a rapid increase in the spherical pore size. In this paper, three tube samples each with different levels of spherical porosity were fabricated by varying the laser energy density for LM-PBF of the IN718 alloy within the stable and higher energy density range and the porosity measured. A low laser energy density was avoided due to balling up, which promotes highly irregular lack of fusion defects and poor consolidation within the alloy microstructure. An orthogonal turning test instrumented, with a three-component dynamometer to measure the cutting forces, was performed on AM produced IN718 tube samples under light cut conditions to simulate a finish machining process. The orthogonal turning tests were also performed on a tube sample obtained from the wrought extruded stock. The machining process parameters, which were studied include varying the cutting speed at three levels, at a fixed feed and under dry cut conditions for a short duration to avoid the tool wear. The results obtained were discussed and a notable finding was the higher rate of built-up-edge formation on the tool tip from the AM samples with a higher porosity and especially at a higher cutting speed. The paper also discusses the mechanisms that underpin the findings.

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Process planning guidelines in selective laser melting for the manufacturing of stainless steel parts

Cited by 17 publications

References 23 publications

Mechanical Properties of AISI 316L Lattice Structures via Laser Powder Bed Fusion as a Function of Unit Cell Features

Mechanical Properties of AISI 316L Lattice Structures via Laser Powder Bed Fusion as a Function of Unit Cell Features

A dimensional assessment of small features and lattice structures manufactured by laser powder bed fusion

Machinability of INCONEL718 Alloy with a Porous Microstructure Produced by Laser Melting Powder Bed Fusion at Higher Energy Densities

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