Down-facing surfaces in laser powder bed fusion of Ti6Al4V: Effect of dross formation on dimensional accuracy and surface texture

Charles, Amal; Elkaseer, Ahmed; Paggi, Umberto; Thijs, Lore; Hagenmeyer, Veit; Scholz, Steffen

doi:10.1016/j.addma.2021.102148

Cited by 28 publications

(13 citation statements)

References 25 publications

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Section: Resultsmentioning

confidence: 99%

“…Consequently, this could cause large dross with less measured roughness, as large melt pools lead to more interconnected melt pools which cannot be detected just by measuring roughness. [37] The thickness of the as-built downskin walls is measured at five points along the length of the sample at a 7 mm distance apart and compared with the CAD model (i.e., 10 mm). The difference between the two gives the deviation in a dimension of the built samples.…”

Section: Dimensional Accuracy Evaluationmentioning

confidence: 99%

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An Experimental Study of Downfacing Surfaces in Selective Laser Melting

et al. 2022

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This article presents an investigative study to evaluate the effect of process parameters on surface roughness and dimensional accuracy of downfacing surfaces. The material used in the study is Corrax steel and is fabricated using selective laser melting (SLM) technology. The fabrication process of the downfacing surface is different from the fabrication of the main or core region due to the poor thermal conductivity of loose powder particles beneath each layer. The processing parameters, namely, laser scanning speed, laser power, and layer reference, are investigated using a full factorial design of experiments method to discover their influence on surface roughness and dimensional deviation. Results show that the investigated factors are significantly affecting the quality of downfacing surfaces and controlling them will greatly influence achieving required surface properties.

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Section: Resultsmentioning

confidence: 99%

Section: Dimensional Accuracy Evaluationmentioning

confidence: 99%

An Experimental Study of Downfacing Surfaces in Selective Laser Melting

et al. 2022

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“…This is known to create high surface roughness [5]. The surface roughness was seen to drop when the LED increased and operated closer to a stable melt-pool condition, such as in a conduction mode [20]. A higher LED can lead to keyhole melt mode of the melt pool that can lead to further surface defects caused by the unstable melt pool [21].…”

Section: Surface Roughnessmentioning

confidence: 99%

Part Tailoring in Metal-Additive Manufacturing: A Step towards Functionally Graded Customized Stainless-Steel Components Using Laser Powder Bed Fusion

et al. 2022

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The aim of this project is to demonstrate a proof of concept by using Additive Manufacturing (AM) technology in order to demonstrate its viability for the production of tailor-made components with regions of varying (higher and lower) hardness and surface roughness within a single part. In order to do this, first a test piece is designed and printed following a full factorial design of the experiment with eight runs with varying process parameters set within different regions of one part. The structure is printed several times with the laser-powder-bed-fusion-based metal-additive-manufacturing system “Sodick LPM 325” using AISI 420 in order to test and validate the change in the achievable mechanical property and surface roughness. The above-mentioned quality marks are characterized using a tactile profilometer, Rockwell test and part density, and the results are statistically analyzed using MATLAB. The results show that the linear energy density plays a significant role in controlling the surface roughness of the top surface of the components while the hardness on the top surface is unaffected. On the side surfaces, it is known that the layer thickness plays a significant role on the surface roughness as well as hardness. Looking at the results obtained, it is seen that the variation in the obtained side surface roughness is not significant to changes in the Linear Energy Density (LED) as the layer thickness was kept constant, with only slight reductions in hardness seen. The annealing process resulted in a significant reduction in hardness. This work has shown that through the careful tailoring of processing conditions, multi-functionality within one part can be integrated and has created promising avenues for further research into achieving fully functionally graded structures.

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“…On the other hand, the combination of several surface roughness parameters might be utilized for textured surfaces [22,23] on which the surface morphology results mostly homogeneously all over the component. For as produced AM components, the surface morphology is highly influenced by several factors [24] such as volumetric energy density, powder particle size, building orientation etc. Each combination of these parameters could result in different as-produced surface topologies, that could degrade the mechanical properties.…”

Section: Introductionmentioning

confidence: 99%