Effect of molten pool boundaries on the mechanical properties of selective laser melting parts

Wen, Shifeng; Li, Shuai; Wei, Qingsong; Yan, Chunze; Zhang, Sheng; Shi, Yusheng

doi:10.1016/j.jmatprotec.2014.06.002

Cited by 386 publications

(149 citation statements)

References 18 publications

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“…Other, more specific, thermal models were developed by Gusarov et al [50], Li et al [51], Fu & Guo [52], Shifeng et al [53], and Heeling et al [54]. Gusarov et al modeled the heat transfer in the material, both conductive and radiative, assuming that the laser scan tracks were nonuniform and that the …”

Section: Temperature Distribution and Heat Transfer Modelsmentioning

confidence: 99%

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Patterson¹,

Messimer²,

Farrington³

2017

Preprint

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A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce fulldensity metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion, and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization, and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging, and design-of-experiments), support structure optimization, and overhang feature design; approximately 140 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs, and potential future research directions are discussed in-depth in light of the present review.

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Section: Temperature Distribution and Heat Transfer Modelsmentioning

confidence: 99%

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Patterson¹,

Messimer²,

Farrington³

2017

Preprint

View full text Add to dashboard Cite

show abstract

“…During the SLM process, therefore, various factors such as applied process parameters and cooling cycles should be optimized carefully, depending on the alloy powder materials used (e.g., type and size distribution) [2,6,13]. In particular, the anisotropy of the mechanical properties is a unique characteristic of SLM builds (Figure 2) [11,12,[14][15][16][17]. The tensile properties of SLM parts fabricated in different building directions depend on the metallurgical bonding between two neighbor melt tracks or layers.…”

mentioning

confidence: 99%

“…The tensile properties of SLM parts fabricated in different building directions depend on the metallurgical bonding between two neighbor melt tracks or layers. When an SLM structure is being built, "layer-layer" and "track-track" molten pool boundaries (MPBs) are generated by multi-layer and multi-track melt pool overlapping, respectively (Figure 2) [16,18]. When the structure is built vertically (90 • ) or horizontally (0 • ), the loading direction caused by an occlusal force would act on the track-track MPB surface or on the layer-layer MPB surface, respectively.…”

mentioning

confidence: 99%

“…Therefore, when a metallic dental structure is fabricated via SLM, the building direction is a primary factor to be considered during the designing process. In addition, it should be noted that the microstructural anisotropy of the SLM part is also caused by the local heat transfer condition, which can be determined by the mean of the scanning strategy [16]. At present, however, there is no definite standard or consensus on how dental SLM prostheses should be designed when considering the anisotropy issue, which mainly depends on the building and scanning strategies.…”

mentioning

confidence: 99%

“…( Figure 2) [11,12,[14][15][16][17]. The tensile properties of SLM parts fabricated in different building directions depend on the metallurgical bonding between two neighbor melt tracks or layers.…”

mentioning

confidence: 99%

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Fabricating High-Quality 3D-Printed Alloys for Dental Applications

2017

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Featured Application: This article will help to find main points to be considered while applying selective laser melting technology in dentistry.Abstract: Metal additive manufacturing (AM), especially selective laser melting (SLM), has been receiving particular attention because metallic functional structures with complicated configurations can be effectively fabricated using the technique. However, there still exist some future challenges for the fabrication of high-quality SLM products for dental applications. First, the surface quality of SLM products should be further improved by standardizing the laser process parameters or by appropriately post-treating the surface. Second, it should be guaranteed that dental SLM restorations have good dimensional accuracy and, in particular, a good marginal fit. Third, a definitive standard regarding building and scanning strategies, which affect the anisotropy, should be established to optimize the mechanical properties and fatigue resistance of SLM dental structures. Fourth, the SLM substructure's bonding and support to veneering ceramic should be further studied to facilitate the use of esthetic dental restorations. Finally, the biocompatibility of SLM dental alloys should be carefully examined and improved to minimize the potential release of toxic metal ions from the alloys. Future research of SLM should focus on solving the above challenges, as well as on fabricating dental structures with "controlled" porosity.Keywords: additive manufacturing; anisotropy; dental alloy; selective laser melting Additive manufacturing (AM), also known as three-dimensional (3D) printing or rapid prototyping, is the process of joining materials to make 3D objects from digital data, usually layer upon layer [1,2]. Metal AM, especially selective laser melting (SLM), has been receiving particular attention because metallic functional structures with complicated configurations in various industrial, medical, and dental sectors can now be fabricated using this technique [1][2][3]. However, due to the complex nature of metal AM, there still exist many challenges for the successful fabrication of high-quality metallic products with favorable microstructures and properties [3]. In particular, several challenges need to be solved in order to apply the SLM technology widely in dental applications, replacing conventional techniques such as casting [1].It has been known that the SLM technique can produce 3D objects with minimal pre-processing and/or post-processing requirements [3]. In reality, however, the supporting structure created in the manufacturing stage must be manually removed after the final 3D product is completed [2,4].

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Monitoring and Quality Assurance for Metal Additive Manufacturing

2021

Metal Additive Manufacturing

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Effect of molten pool boundaries on the mechanical properties of selective laser melting parts

Cited by 386 publications

References 18 publications

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

Fabricating High-Quality 3D-Printed Alloys for Dental Applications

Monitoring and Quality Assurance for Metal Additive Manufacturing

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