Areal Analysis Investigation of Selective Laser Melting Parts

Abstract

Selective laser melting is an additive manufacturing technology used to fabricate metal parts characterized by complex geometries that are difficult or impossible to produce with conventional production methods. One of the major drawbacks of laser melting is the poor surface quality that typically is not satisfactory for functional applications. The aim of this work is to use areal analysis to characterize selective laser melting surfaces. The results highlight a marked variability and anisotropy that cannot be evaluated through traditional measurement. The building orientation and secondary finishing operations are analyzed and discussed. Findings demonstrate how areal analysis can be used to determine how to implement barrel finishing with the aim of reducing anisotropy and increasing surface quality.

A Review on Wire-Laser Directed Energy Deposition: Parameter Control, Process Stability, and Future Research Paths

“…By modifying the lateral overlap between adjacent beads, Bernauer et al demonstrated that an optimal overlapping distance exists, at which good wettability and surface quality can be achieved [56,125]. Sheikh et al measured the average surface roughness (R a ) [147] of layers deposited using different lateral overlap ratios and achieved an R a lower than 8 µm for the optimum overlap ratio employing SS304 wire with a 100 μm diameter as depicted in Figure 17 [65]. Consistent with these findings, several studies stated that exceeding the optimal lateral overlap leads to reduced material efficiency and accuracy, whereas low lateral overlap compromises surface topography [58,148].…”