Effects of build- and scan-directions on magnetic field-assisted finishing of 316L stainless steel disks produced with selective laser melting

Wu, Pei‐Ying; Hirtler, Markus�; Bambach, Markus; Yamaguchi, Hitomi

doi:10.1016/j.cirpj.2020.08.010

Cited by 12 publications

(5 citation statements)

References 36 publications

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“…Based on the previous study, 14 the temperature distribution and heat accumulation were found to have a significant impact on island size. Pary et al 15 and Ali et al 16 showed that high-temperature accumulation within the molten pool increased melt depth, particularly in the case of smaller island sizes.…”

Section: Resultsmentioning

confidence: 85%

Influence of hexagonal scanning strategy island size on microstructure, residual stress, and corrosion behavior of 17-4 PH SS made by L-PBF

Sarma

Selvaraj

Kumar

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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17-4 Precipitation-hardened steel has attracted worldwide attention due to its applications. In the manufacture of 17-4 PH SS using SLM, several parameters play an important role. In the present study, the hexagonal island sizes were varied as 1.25-2.5-3.75-5-6.75-7.5-8.75-10 mm to understand the microstructure, microhardness, residual stresses, and corrosion behavior of 17-4 precipitation hardened stainless steel fabricated by laser-powder bed fusion with a scan rotation angle of 90°. The results indicate that the average time per layer decreases as the island size increases. The quality of the surface increased with a decrease in hexagonal island size as scan length reduced. The hardness varied with island size and higher hardness was exhibited due to fine grain size. The medium island size microstructure consists of regular molten pools and lower heat accumulation. Large and small molten pools were observed on the front and side surface respectively for samples with different hexagonal island sizes. Austenite phase was detected in all samples with the highest intensity at hexagonal inside out sample with an island size of 2.5 mm at 43.500°. Both hexagonal samples with 2.5 mm island size and 10 mm samples almost exhibit ɣ-austenite phase in the finer grain size area, as per EBSD orientation maps. The residual stresses increased as the hexagonal island size increased because when a large island size is used, it produces a long scanning track with a weak pre-heating effect, resulting in a high-temperature gradient and high residual stress. Higher corrosion resistance was obtained for 2.5 mm hexagonal scan strategy island size because of finer grain size and lower defects.

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Section: Resultsmentioning

confidence: 85%

Influence of hexagonal scanning strategy island size on microstructure, residual stress, and corrosion behavior of 17-4 PH SS made by L-PBF

Sarma

Selvaraj

Kumar

2022

Proceedings of the Institution of Mechanical Engineers, Part L:

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“…With the development of metal additive manufacturing (AM) [5][6][7][8][9], which is capable of producing various complex designs and shapes that are not feasible with any conventional subtractive manufacturing, there has been an increasing demand for viable finishing technologies for complex AM-fabricated geometries. Although there are other advanced finishing processes that can improve the surface quality of the parts to a fine scale such as elastic emission machining (EEM) [10] and chemical-mechanical polishing (CMP) [11], thanks to the shape-adaptive flexible polishing brush, MAF has garnered much interest regarding the post processing of additively manufactured components [12][13][14]. The MAF process was implemented to polish various kinds of materials, such as mold steels [15], glass [16], ceramics [17], sheet metals [18], and titanium alloys [19].…”

Section: Introductionmentioning

confidence: 99%

“…Lubricants 2023, 11, x FOR PEER REVIEW 2 of 23 surface quality of the parts to a fine scale such as elastic emission machining (EEM) [10] and chemical-mechanical polishing (CMP) [11], thanks to the shape-adaptive flexible polishing brush, MAF has garnered much interest regarding the post processing of additively manufactured components [12][13][14]. The MAF process was implemented to polish various kinds of materials, such as mold steels [15], glass [16], ceramics [17], sheet metals [18], and titanium alloys [19].…”

Section: Introductionmentioning

confidence: 99%

Novel Process Modeling of Magnetic-Field Assisted Finishing (MAF) with Rheological Properties

et al. 2023

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The performance of a magnetic-field-assisted finishing (MAF) process, an advanced surface finishing process, is severely affected by the rheological properties of an MAF brush. The yield stress and viscosity of the MAF brush, comprising iron particles and abrasives mixed in a liquid carrier medium, change depending on the brush’s constituents and the applied magnetic field, which in turn affect the material removal mechanism and the corresponding final surface roughness after the MAF. A series of experiments was conducted to delineate the effect of MAF processing conditions on the yield stress of the MAF brush. The experimental data were fitted into commonly used rheology models. The Herschel–Bulkley (HB) model was found to be the most suitable fit (lowest sum of square errors (SSE)) for the shear stress–shear rate data obtained from the rheology tests and used to calculate the yield stress of the MAF brush. Processing parameters, such as magnetic flux density, weight ratio of iron and abrasives, and abrasive (black ceramic in this study) size, with p-values of 0.031, 0.001 and 0.037, respectively, (each of them lower than the significance level of 0.05), were all found to be statistically significant parameters that affected the yield stress of the MAF brush. Yield stress increased with magnetic flux density and the weight ratio of iron to abrasives in MAF brush and decreased with abrasive size. A new process model, a rheology-integrated model (RM), was formulated using the yield stress data from HB model to determine the indentation depth of individual abrasives in the workpiece during the MAF process. The calculated indentation depth enabled us to predict the material removal rate (MRR) and the instantaneous surface roughness. The predicted MRR and surface roughness from the RM model were found to be a better fit with the experimental data than the pre-existing contact mechanics model (CMM) and wear model (WM) with a R2 of 0.91 for RM as compared to 0.76 and 0.78 for CMM and WM. Finally, the RM, under parametric variations, showed that MRR increases and roughness decreases as magnetic flux density, rotational speed, weight ratio of iron to abrasive particles in MAF brush, and initial roughness increase, and abrasive size decreases.

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“…Usando o processo de MAF, Yamaguchi, Fergani e Wu (2017) relataram uma melhoria na rugosidade da superfície de 102,1±3,8 µm 0,13±0,07 µm (R z ) em 240 min de tempo de polimento de componentes de 316L SS produzidos por SLM. Wu et al (2020) reduziram a rugosidade inicial (80,6±19,6 µm R z após SLM) para aproximadamente 3 µm R z em 105 min de tempo de polimento. Zhang e Wang (2022) usaram esferas de imãs revestidas por MAF para melhorar a qualidade superficial dos tubos de 316L SS produzidos por L-PBF.…”

Section: Fabricação (E Pós-processamento)unclassified

“…Os autores também desenvolveram um modelo analítico da taxa de remoção de material que correlaciona a rugosidade com a profundidade de indentação dos abrasivos no processo de MAF. Wu et al (2020) analisaram o efeito da estratégia de construção sobre os resultados do processo de MAF (rugosidade, dureza e tensão residual), em peças (discos) de 316L feitos por SLM. Três direções de construção foram analisadas, sendo elas: horizontal (H), vertical paralelo (V // ) e vertical perpendicular (V ⊥ ).…”

Section: Pós-processamento Via Maf De Peças Feitas Por Maunclassified

Pós-processamento de peças metálicas produzidas por manufatura aditiva

Souza¹

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Aos meus pais, Antônio e Vilma, pelo amor e incentivo constante.Ao Prof. Eraldo Jannone da Silva, cuja orientação, paciência e as constantes ajudas proporcionaram o desenrolar deste trabalho. À Prof.ª Hitomi Yamaguchi Greenslet por todo suporte e permitir a realização do estágio no exterior. Muito obrigado por expandir meus horizontes relacionados à manufatura.À minha noiva, Flávia Sanches, pelo carinho e amor, desde o início deste trabalho.À minha madrinha, Vânia Leite, pelo enorme carinho.Aos membros do grupo do Laboratório de Processos Avançados e Sustentabilidade (LAPRAS) e do Nontraditional Manufacturing Laboratory (NTML).Ao Prof. Reginaldo Coelho Teixeixa por me permitir vincular esta pesquisa ao Projeto Temático (2016/11309-0) e pelo apoio financeiro e científico. Ao Prof. André Capaldo Amaral pelas análises biológicas.Ao Prof. Carlos Alberto Fortulan pelo auxílio na preparação da termocera. Ao Prof. Gherhardt Ribatski pelo empréstimo da câmara de alta velocidade.Ao Prof. Nelson Batista de Lima pelas análises de tensão residual.Aos técnicos, Adolfo Ferrarin, José Botelho e Tiago Camponucci, pela ajuda nos procedimentos operacionais.Aos meus colegas de Medeiros-MG, pelos momentos de descontração.À Blaser Swisslube do Brasil Ltda, em especial ao Marcelo Kuroda, pela doação do fluido de corte.Ao Materials Institute of Brazil (MIB), em especial ao Marcelo Milan, pela colaboração. À Saint-Gobain Abrasives, em especial ao Marcelo Sasaki e Fabio Freitas, pela doação dos rebolos e abrasivos.À Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP), processo 2019/10758-4, pela concessão da bolsa de estudos.A todos estes colaboradores, meu sincero agradecimento.Por fim, agradeço a todos que de alguma forma contribuíram para este trabalho.

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Effects of build- and scan-directions on magnetic field-assisted finishing of 316L stainless steel disks produced with selective laser melting

Cited by 12 publications

References 36 publications

Influence of hexagonal scanning strategy island size on microstructure, residual stress, and corrosion behavior of 17-4 PH SS made by L-PBF

Influence of hexagonal scanning strategy island size on microstructure, residual stress, and corrosion behavior of 17-4 PH SS made by L-PBF

Novel Process Modeling of Magnetic-Field Assisted Finishing (MAF) with Rheological Properties

Pós-processamento de peças metálicas produzidas por manufatura aditiva

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