Assessing dependency of part properties on the printing location in laser-powder bed fusion metal additive manufacturing

Mussatto, Andre; Groarke, Robert; Vijayaraghavan, Rajani K.; Hughes, Cian; Obeidi, Muhannad Ahmed; Doğu, Merve Nur; Yalçın, Mustafa; McNally, Patrick J.; Delauré, Yan; Brabazon, Dermot

doi:10.1016/j.mtcomm.2022.103209

Cited by 15 publications

(7 citation statements)

References 83 publications

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“…Some authors have reported higher differences and attributed them to density/porosity differences between the production areas. These porosity fluctuations were linked to heterogeneities in the spatter distribution [24,25]. However, in this study, no variation in the density was reported, except for area 2, which had a lower relative density but did not present a drop in elongation, as noted by [24].…”

Section: Effect Of Sample Positioning On Fabrication Plateformcontrasting

confidence: 54%

“…These porosity fluctuations were linked to heterogeneities in the spatter distribution [24,25]. However, in this study, no variation in the density was reported, except for area 2, which had a lower relative density but did not present a drop in elongation, as noted by [24]. Moreover, the fracture energies as a function of the building and notch orientations did not evolve as a function of the production area.…”

Section: Effect Of Sample Positioning On Fabrication Plateformcontrasting

confidence: 51%

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In Situ Ageing with the Platform Preheating of AlSi10Mg Alloy Manufactured by Laser Powder-Bed Fusion Process

Chambrin

Dalverny

Cloué³

et al. 2022

Metals

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AlSi10Mg alloy is mainly produced by laser fusion on a powder bed. It offers a good compromise between easy processing and good mechanical properties. These properties depend on the manufacturing parameters, including the preheating temperature, as this alloy hardens by precipitation. This study explored the effect of preheating to 170 °C on the mechanical properties and microstructure of this alloy as a function of the manufacturing time. The mechanical properties were characterized by tensile, hardness and impact strength tests as a function of the sample height. An anisotropic behavior was confirmed: the horizontal orientation showed higher deformation and fracture energies. In addition, a gradient of properties appeared as a function of the distance from the platform; the closer the sample was to the platform, the higher its fracture energy and the lower its hardness. The hardness values followed the same evolution as a function of the distance to the platform as that of the hardness curve after ageing post-treatment. It was therefore shown that the preheating of the platform generated in situ ageing with respect to the manufacturing height: a hardness peak was obtained at a certain distance from the plateau (40 mm—10 h of remaining manufacturing time) and over-aging near the plateau was induced by long exposure times at 170 °C.

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Section: Effect Of Sample Positioning On Fabrication Plateformcontrasting

confidence: 54%

Section: Effect Of Sample Positioning On Fabrication Plateformcontrasting

confidence: 51%

In Situ Ageing with the Platform Preheating of AlSi10Mg Alloy Manufactured by Laser Powder-Bed Fusion Process

Chambrin

Dalverny

Cloué³

et al. 2022

Metals

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“…Each batch contained vertically and horizontally aligned samples, as illustrated in Figure 1, to allow in-plane and through-plane measurement via flash diffusivity, respectively. It is worth noting, other build parameters such as shielding gas flow rate (Reijonen et al , 2020), recoating speed (Phua et al , 2021), particle size distribution of the powder (Bonesso et al , 2021), power degradation (Raza et al , 2021) and geometry of the parts (Jones et al , 2021) and their location on the build plate (Mussatto et al , 2022) can affect the porosity and hence the thermal performance of the fabricated part which should be investigated in the future work. Furthermore, process variation based on build design can affect residual stress (Pant et al , 2020) and the thermal history, which could affect microstructure.…”

Section: Methodsmentioning

confidence: 99%

Process-dependent anisotropic thermal conductivity of laser powder bed fusion AlSi10Mg: impact of microstructure and aluminum-silicon interfaces

Azizi

Hejripour

Goodman

et al. 2023

RPJ

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Purpose AlSi10Mg alloy is commonly used in laser powder bed fusion due to its printability, relatively high thermal conductivity, low density and good mechanical properties. However, the thermal conductivity of as-built materials as a function of processing (energy density, laser power, laser scanning speed, support structure) and build orientation, are not well explored in the literature. This study aims to elucidate the relationship between processing, microstructure, and thermal conductivity. Design/methodology/approach The thermal conductivity of laser powder bed fusion (L-PBF) AlSi10Mg samples are investigated by the flash diffusivity and frequency domain thermoreflectance (FDTR) techniques. Thermal conductivities are linked to the microstructure of L-PBF AlSi10Mg, which changes with processing conditions. The through-plane exceeded the in-plane thermal conductivity for all energy densities. A co-located thermal conductivity map by frequency domain thermoreflectance (FDTR) and crystallographic grain orientation map by electron backscattered diffraction (EBSD) was used to investigate the effect of microstructure on thermal conductivity. Findings The highest through-plane thermal conductivity (136 ± 2 W/m-K) was achieved at 59 J/mm3 and exceeded the values reported previously. The in-plane thermal conductivity peaked at 117 ± 2 W/m-K at 50 J/mm3. The trend of thermal conductivity reducing with energy density at similar porosity was primarily due to the reduced grain size producing more Al-Si interfaces that pose thermal resistance. At these interfaces, thermal energy must convert from electrons in the aluminum to phonons in the silicon. The co-located thermal conductivity and crystallographic grain orientation maps confirmed that larger colonies of columnar grains have higher thermal conductivity compared to smaller columnar grains. Practical implications The thermal properties of AlSi10Mg are crucial to heat transfer applications including additively manufactured heatsinks, cold plates, vapor chambers, heat pipes, enclosures and heat exchangers. Additionally, thermal-based nondestructive testing methods require these properties for applications such as defect detection and simulation of L-PBF processes. Industrial standards for L-PBF processes and components can use the data for thermal applications. Originality/value To the best of the authors’ knowledge, this paper is the first to make coupled thermal conductivity maps that were matched to microstructure for L-PBF AlSi10Mg aluminum alloy. This was achieved by a unique in-house thermal conductivity mapping setup and relating the data to local SEM EBSD maps. This provides the first conclusive proof that larger grain sizes can achieve higher thermal conductivity for this processing method and material system. This study also shows that control of the solidification can result in higher thermal conductivity. It was also the first to find that the build substrate (with or without support) has a large effect on thermal conductivity.

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“…The direct replicability of 3D printing assumed in prior forecasts require both repeatability and reproducibility (Khorasani et al, 2021; Mussatto et al, 2022; Salmi et al, 2013). Repeatability means creating identical objects using the same operator, environment, and equipment (e.g., 3D printer, software, materials) in a short interval of time.…”

Section: Reverse Salients In 3d Printingmentioning

confidence: 99%

Where digital meets physical innovation: Reverse salients and the unrealized dreams of3Dprinting

Rayna

West

2023

J of Product Innov Manag

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For more than three decades, enthusiasts have predicted that direct manufacturing enabled by 3D printing would inevitably supplant traditional manufacturing methods. Alas, for nearly as long, these utopian predictions have failed to materialize. One reason is a flawed assumption that hybrid digital-physical systems such as 3D printing would advance as rapidly as purely digital innovations enabled by Moore's law. Instead, like other examples of cyber-physical systems (CPSs), technological progress in 3D printing faces inherent limitations that are emblematic of the differences between CPSs and purely digital innovations. As with any complex CPS, improved performance of a 3D printing system has been limited by that of its key components-the sort of limiting problem previously defined as a reverse salient. Unlike previously studied technologies, several reverse salients for 3D printing performance have neither resolved nor signs of resolving soon.Here we analyze these key reverse salients, and show how they have hampered the suitability of 3D printing for direct manufacturing and other predicted applications. We contrast predicted versus actual capabilities for 3D printing-enabled transformation in six key areas: product innovation, mass customization, home fabrication, distributed manufacturing, supply chain optimization and business model innovation. From this, we suggest opportunities for greater realism in future 3D printing research, as well as broader implications for our understanding of CPSs and reverse salients.

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Assessing dependency of part properties on the printing location in laser-powder bed fusion metal additive manufacturing

Cited by 15 publications

References 83 publications

In Situ Ageing with the Platform Preheating of AlSi10Mg Alloy Manufactured by Laser Powder-Bed Fusion Process

In Situ Ageing with the Platform Preheating of AlSi10Mg Alloy Manufactured by Laser Powder-Bed Fusion Process

Process-dependent anisotropic thermal conductivity of laser powder bed fusion AlSi10Mg: impact of microstructure and aluminum-silicon interfaces

Where digital meets physical innovation: Reverse salients and the unrealized dreams of3Dprinting

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