Development and experimental study of an automated laser-foil-printing additive manufacturing system

Hung, Chia-Hung; Turk, Tunay; Sehhat, M. Hossein; Leu, Ming C.

doi:10.1108/rpj-10-2021-0269

Cited by 18 publications

(8 citation statements)

References 34 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…In LFP, a continuous-wave (CW) fiber laser and a pulse laser are used to weld and cut metal foil on the substrate for the fabrication of metallic parts layer by layer. An automated LFP additive manufacturing system was built to enhance process productivity and parts’ accuracy (Hung et al , 2022). Additionally, a prediction model of melt pool size using different process parameters in LFP for aluminum alloy 1100 was investigated to simplify parametric studies (Sehhat et al , 2021).…”

Section: Introductionmentioning

confidence: 99%

Fabrication of crack-free aluminum alloy 6061 parts using laser foil printing process

Wang,

Hung,

Pommerenke

et al. 2024

RPJ

Self Cite

View full text Add to dashboard Cite

Purpose This paper aims to present the fabrication of 6061 aluminum alloy (AA6061) using a promising laser additive manufacturing process, called the laser-foil-printing (LFP) process. The process window of AA6061 in LFP was established to optimize process parameters for the fabrication of high strength, dense and crack-free parts even though AA6061 is challenging for laser additive manufacturing processes due to hot-cracking issues. Design/methodology/approach The multilayers AA6061 parts were fabricated by LFP to characterize for cracks and porosity. Mechanical properties of the LFP-fabricated AA6061 parts were tested using Vicker’s microhardness and tensile testes. The electron backscattered diffraction (EBSD) technique was used to reveal the grain structure and preferred orientation of AA6061 parts. Findings The crack-free AA6061 parts with a high relative density of 99.8% were successfully fabricated using the optimal process parameters in LFP. The LFP-fabricated parts exhibited exceptional tensile strength and comparable ductility compared to AA6061 samples fabricated by conventional laser powder bed fusion (LPBF) processes. The EBSD result shows the formation of cracks was correlated with the cooling rate of the melt pool as cracks tended to develop within finer grain structures, which were formed in a shorter solidification time and higher cooling rate. Originality/value This study presents the pioneering achievement of fabricating crack-free AA6061 parts using LFP without the necessity of preheating the substrate or mixing nanoparticles into the melt pool during the laser melting. The study includes a comprehensive examination of both the mechanical properties and grain structures, with comparisons made to parts produced through the traditional LPBF method.

show abstract

Section: Introductionmentioning

confidence: 99%

Fabrication of crack-free aluminum alloy 6061 parts using laser foil printing process

Wang,

Hung,

Pommerenke

et al. 2024

RPJ

Self Cite

View full text Add to dashboard Cite

show abstract

“…Depending on the type of AM process, the format of material feedstock is different. For instance, Laser Foil Printing (LFP) uses metal foils while Fused Deposition Modeling (FDM) uses laments [13][14][15][16][17]. The powder is another widespread material format in AM, especially in powder-based AM processes [18][19][20].…”

Section: Introductionmentioning

confidence: 99%

Experimental approach for development of a powder spreading metric in additive manufacturing

Sehhat

Sutton

Yates

et al. 2023

Int J Adv Manuf Technol

Self Cite

View full text Add to dashboard Cite

The powder spreading is a vital step of powder-based Additive Manufacturing (AM) processes. The quality of spread powder can considerably in uence the properties of fabricated parts. Poorly-packed powder beds with high surface roughness result in printed part layers with large porosity and low dimensional accuracy, leading to poor mechanical properties. Therefore, the powder spreadability and its dependence on process parameters and powder characteristics should be quanti ed to improve the e ciency of powder-based AM methods. This study proposes a novel dimensionless powder spreadability metric that can be commonly used in different powder-based AM processes. The quality of spread powder in terms of powder bed density and surface roughness was evaluated by adjusting the process parameters, including recoating velocity and layer thickness, and powder characteristics, including particle size distribution. In addition, the dynamic repose angle was proposed and examined as another powder spreadability metric. The results showed that these two proposed metrics were strongly correlated, and lower recoating velocity and larger layer thickness led to higher spreadability and lower dynamic repose angle.

show abstract

“…Additive Manufacturing (AM) has improved the traditional method of part production through the elimination of several inner-process manufacturing steps, and post-processing like heat treatment [1][2][3][4]. The layer-by-layer production fashion of AM can fabricate parts with complicated geometries in a single-step process [5][6][7][8][9][10]. Researchers have extensively investigated the AM from different viewpoints in the past decade.…”

Section: Introductionmentioning

confidence: 99%

Verification of stress transformation in anisotropic material additively manufactured by fused deposition modeling (FDM)

Sehhat

Mahdianikhotbesara

Yadegari

2022

Int J Adv Manuf Technol

View full text Add to dashboard Cite

The widespread use of Additive Manufacturing (AM) has been extensively progressed in the past decade due to the convenience provided by AM in rapid and reliable part production. Fused Deposition Modeling (FDM) has witnessed even faster growth of application as its equipment is environmentally-friendly and easily adaptable. This increased use of FDM to manufacture prototypes and nished parts is accompanied by concerns that 3D printed parts do not perform the same as relatively homogeneous parts produced by molding or machining. As the interface between two faces of bonded material may be modeled by stress elements, in theory by modeling 3D printed layers subjected to tension at varying angles as transformed stress elements, the stress required to break the layer bonds can be determined. To evaluate such a relationship, in this study, the stresses calculated from stress transformation were compared with the behavior of 3D printed specimens subjected to tensile loads. The maximum principal stress was found to be constant relative to the layer angle, regardless of whether the specimen experienced failure at the layer interface or within the layer material, although the specimens with layers 75° relative to the load were notable exceptions to this nding. This failure at much lower stresses for the samples used in the 75° tests may be attributed to a possible environmental factor, such as temperature or humidity change, degrading the samples' structural integrity.

show abstract

Development and experimental study of an automated laser-foil-printing additive manufacturing system

Cited by 18 publications

References 34 publications

Fabrication of crack-free aluminum alloy 6061 parts using laser foil printing process

Fabrication of crack-free aluminum alloy 6061 parts using laser foil printing process

Experimental approach for development of a powder spreading metric in additive manufacturing

Verification of stress transformation in anisotropic material additively manufactured by fused deposition modeling (FDM)

Contact Info

Product

Resources

About