Effect of Process Parameters on the Surface Roughness of Overhanging Structures in Laser Powder Bed Fusion Additive Manufacturing

Fox, Jason C.; Moylan, Shawn P.; Lane, Brandon

doi:10.1016/j.procir.2016.02.347

Cited by 311 publications

(127 citation statements)

References 10 publications

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“…But they reported that reducing the spanned distance can improve manufacturability for low inclination struts. Similar surface roughness results of Leary et al were found by Fox et al [53], Triantaphyllou et al…”

Section: Introductionsupporting

confidence: 88%

“…Zhang et al [39] suggested using three times bigger pore sizes. Furthermore, as reported by several authors [52][53][54][55][56][57][58], the difference between the realized and planned diameter of struts is a function of strut inclination. Therefore, one can expect a lattice having different diameter struts after printing even if a lattice having equal diameter struts are intended.…”

Section: Finite Size Powder Problemmentioning

confidence: 72%

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Numerical prediction of the printable density range of lattice structures for additive manufacturing

2017

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Structured cellular structures are nowadays printed using additive manufacturing methods like powder bed fusion. The relative density of the cellular structures has a big role in the suitability of a lattice for printing due to the minimum printable radius constraint and powder being trapped inside an inclusion. In this work, the theoretical limits of the printable range of relative density of different lattice types are found based on the cell size using computer methods by leaving other process parameters for further research as the current parameters are the most basic ones. The results are approximated using simple polynomials to enable practical usage.

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Section: Introductionsupporting

confidence: 88%

Section: Finite Size Powder Problemmentioning

confidence: 72%

Numerical prediction of the printable density range of lattice structures for additive manufacturing

2017

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“…The particles that adhere on the surface decrease the roughness because some unevenness gets filled. Fox et al [44] found in their work a shift between surfaces dominated by partially melted powder particles and surfaces dominated by material from the re-solidified melt track. With a decrease of the surface angle, the Ra value increased.…”

Section: Vickers Hardnessmentioning

confidence: 93%

Comparison of Single Ti6Al4V Struts Made Using Selective Laser Melting and Electron Beam Melting Subject to Part Orientation

Weißmann

Drescher

Bader

et al. 2017

Metals

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Abstract:The use of additive manufacturing technologies to produce lightweight or functional structures is widespread. Especially Ti 6 Al 4 V plays an important role in this development field and parts are manufactured and analyzed with the aim to characterize the mechanical properties of open-porous structures and to generate scaffolds with properties specific to their intended application. An SLM and an EBM process were used respectively to fabricate the Ti 6 Al 4 V single struts. For mechanical characterization, uniaxial compression tests and hardness measurements were conducted. Furthermore, the struts were manufactured in different orientations for the determination of the mechanical properties. Roughness measurements and a microscopic characterization of the struts were also carried out. Some parts were characterized following heat treatment (hot isostatic pressing). A functional correlation was found between the compressive strength and the slenderness ratio (λ) as well as the equivalent diameter (d) and the height (L) of EBM and SLM parts. Hardness investigations revealed considerable differences related to the microstructure. An influence of heat treatment as well as of orientation could be determined. In this work, we demonstrate the influence of the fabrication quality of single struts, the roughness and the microstructure on mechanical properties as a function of orientation.

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“…Other works that addressed the concern of overhanging feature stresses in SLM/DMLS were those by Wang et al [31,137,138], Cloots et al [139], Fox et al [140] and Kruth et al [141]. The focus of the studies performed by Wang et al was the design of curved overhanging parts and parts set at small angles, so designed that they did not need significant support material.…”

Section: Overhanging Feature Designmentioning

confidence: 99%

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

2017

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Abstract: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 full-density 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 the 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 143 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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Effect of Process Parameters on the Surface Roughness of Overhanging Structures in Laser Powder Bed Fusion Additive Manufacturing

Cited by 311 publications

References 10 publications

Numerical prediction of the printable density range of lattice structures for additive manufacturing

Numerical prediction of the printable density range of lattice structures for additive manufacturing

Comparison of Single Ti6Al4V Struts Made Using Selective Laser Melting and Electron Beam Melting Subject to Part Orientation

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

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