Design of experiments approach in AZ31 powder selective laser melting process optimization

Pawlak, A.; Rosienkiewicz, Maria; Chlebus, Edward

doi:10.1016/j.acme.2016.07.007

Cited by 69 publications

(29 citation statements)

References 15 publications

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“…Pawlak et al [83,84] suggested that the design of experiments methods is used to facilitate the optimisation of the L-PBF process for AZ31 alloy. The high relative densities and high hardness of the alloy that exceed the values obtained for wrought material further confirm that magnesium alloys are suitable for the L-PBF processing.…”

Section: The Use Of L-pbf Technology For Magnesium Processingmentioning

confidence: 99%

The potential of SLM technology for processing magnesium alloys in aerospace industry

Kurzynowski

Pawlak

Smolina

2020

Archiv.Civ.Mech.Eng

100

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Selective Laser Melting (SLM) of magnesium alloys is the technology undergoing dynamic development in many research centres. The results are promising and make it possible to manufacture defect-free material with better properties than those offered by the manufacturing technologies used to date. This review aims to evaluate present state as well as main challenges of using Laser Powder Bed Fusion (L-PBF) for processing magnesium alloys as an alternative way to conventional technologies to manufacture parts in the aerospace industry. This literature review is the first one to outline information concerning the potential to use magnesium alloys in the aerospace industry as well as to summarise the results of magnesium alloy processing using AM technologies, in particular L-PBF. The available literature was reviewed to gather information about: the use of magnesium alloys in the aerospace industry-the benefits and limitations of using magnesium and its alloys, examples of applications using new processing methods to manufacture aerospace parts, the benefits and potential of using L-PBF to process metallic materials, examples of the use of L-PBF to manufacture aerospace parts, and state-of-the-art research into L-PBF processing of magnesium and magnesium alloys.

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Section: The Use Of L-pbf Technology For Magnesium Processingmentioning

confidence: 99%

The potential of SLM technology for processing magnesium alloys in aerospace industry

Kurzynowski

Pawlak

Smolina

2020

Archiv.Civ.Mech.Eng

100

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“…(1)). The aforementioned parameters are general and do not allow for precise determination of energy, therefore, linear energy density can be treated as an optimization parameter [8], [15], [21], whereas scan velocity depends on time exposure (t expo ) of laser on single point and pre-defined distance between these points (Eq. 2).…”

Section: Design Of Experimentsmentioning

confidence: 99%

“…This study is based on design of experiment (DOE) approach to optimize the process and experiment algorithm presented in the research [21]. In order to reduce the amount of experiments, three factors have been chosen as variable for tree level full factorial 3 K design.…”

Section: Design Of Experimentsmentioning

confidence: 99%

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Development of manufacturing method of the MAP21 magnesium alloy prepared by selective laser melting (SLM)

Gruber

Mackiewicz

Stopyra

et al. 2019

Acta Bioeng Biomech

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Magnesium alloys are well known for their biocompatibility and biodegradable properties [9], [27] owing to the fact that magnesium is a mineral crucial for human body, especially for bone tissue. There are studies [17] on using WE43 additively manufactured magnesium scaffolds for full bone and soft tissue regeneration. Moreover, magnesium implants in bones were investigated as having higher bone-implant interface strength than titanium ones [3]. In this paper, the results of the studies on MAP21 magnesium powder selective laser melting process optimization as a starting point for further bioapplications are presented. MAP21 magnesium alloy owing to its high mechanical properties, excellent vibration damping characteristic and good creep resistance is a promising material to be tested for scaffold structures. The study for the first time shows successful SLM manufacturing of dense samples made of MAP21 alloy. Using an algorithm based on design of experiment (DoE) method [21], the SLM process parameters were designated. The porosity was investigated as a SLM process optimization parameter. High density of produced sample, up to 99%, was achieved. Microstructure and oxidation level after selective laser melting (SLM) manufacturing were characterized. Fine grain microstructure and three kinds of precipitations were found Nd (Gd, Zr, Mg), Mg (Nd, Gd, Zr) and Mg (Zr, Nd, Gd, Zn)). In order to determine the mechanical properties of MAP21 alloy processed with SLM technology, static tensile tests and microhardness tests were conducted, resulting in mechanical properties (R m = 167 MPa, E = 38.6 GPa, 63-74 HB) comparable with as-cast alloy. A discussion was held on further research opportunities for biomedical use of SLM-ed MAP21 alloy.

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“…They concluded that hatch spacing was the parameter with the most significant influence. Using the same approach, Pawlak et al [29] fabricated AZ31 magnesium parts with relative densities higher than 99.5% using the L-PBF process. Sharma et al [30] used the Taguchi method and RSM to investigate the influence of the laser power, scanning speed, and hatch spacing on density and surface roughness of PBF-fabricated AlSi10 Mg samples and reported the hatch spacing as the most significant factor in determining the output responses.…”

Section: Introductionmentioning

confidence: 99%

Modeling and Optimization Approaches of Laser-Based Powder-Bed Fusion Process for Ti-6Al-4V Alloy

2020

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Laser-based powder-bed fusion (L-PBF) is a widely used additive manufacturing technology that contains several variables (processing parameters), which makes it challenging to correlate them with the desired properties (responses) when optimizing the responses. In this study, the influence of the five most influential L-PBF processing parameters of Ti-6Al-4V alloy—laser power, scanning speed, hatch spacing, layer thickness, and stripe width—on the relative density, microhardness, and various line and surface roughness parameters for the top, upskin, and downskin surfaces are thoroughly investigated. Two design of experiment (DoE) methods, including Taguchi L25 orthogonal arrays and fractional factorial DoE for the response surface method (RSM), are employed to account for the five L-PBF processing parameters at five levels each. The significance and contribution of the individual processing parameters on each response are analyzed using the Taguchi method. Then, the simultaneous contribution of two processing parameters on various responses is presented using RSM quadratic modeling. A multi-objective RSM model is developed to optimize the L-PBF processing parameters considering all the responses with equal weights. Furthermore, an artificial neural network (ANN) model is designed and trained based on the samples used for the Taguchi method and validated based on the samples used for the RSM. The Taguchi, RSM, and ANN models are used to predict the responses of unseen data. The results show that with the same amount of available experimental data, the proposed ANN model can most accurately predict the response of various properties of L-PBF components.

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Design of experiments approach in AZ31 powder selective laser melting process optimization

Cited by 69 publications

References 15 publications

The potential of SLM technology for processing magnesium alloys in aerospace industry

The potential of SLM technology for processing magnesium alloys in aerospace industry

Development of manufacturing method of the MAP21 magnesium alloy prepared by selective laser melting (SLM)

Modeling and Optimization Approaches of Laser-Based Powder-Bed Fusion Process for Ti-6Al-4V Alloy

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