Efficient optimization methodology for laser powder bed fusion parameters to manufacture dense and mechanically sound parts validated on AlSi12 alloy

Gheysen, Julie; Marteleur, Matthieu; Rest, Camille van der; Simar, Aude

doi:10.1016/j.matdes.2020.109433

Cited by 27 publications

(12 citation statements)

References 40 publications

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“…To produce SSTs, only P and v can be varied, but a wide range of their combinations can be explored, thanks to rapid production and analysis. Considering the width and the continuity of entire SSTs in an on-top investigation and the cross-section morphologies, a restricted range of P–v combinations suitable for bulk production can be quickly identified [ 57 , 58 , 59 ]. The SSTs cross-sectional analysis involves a complex and time-consuming sample preparation procedure however the on-top evaluation is strongly affected by the operator error.…”

Section: Pre-processingmentioning

confidence: 99%

“…To numerically evaluate the quality of a SST, an automatic computer-aided method was recently developed by the authors in a previously published work [ 60 ]. Although this approach still requires a DOE of bulk samples for full optimisation, a further streamlining of the procedure was enabled by Gheysen et al [ 59 ] and Bosio et al [ 61 ] who developed a method to derive the optimal hd value directly from SSTs. In particular, the optimal hd value can be set by calculating the width of the SSTs and considering an adequate overlapping among them.…”

Section: Pre-processingmentioning

confidence: 99%

“…In particular, the optimal hd value can be set by calculating the width of the SSTs and considering an adequate overlapping among them. The latter can be fix at 0% as recommended in Bosio et al [ 61 ] or calculated considering some geometrical on top parameters of the SST using the equation developed by Gheysen et al [ 59 ]. Although the SST approach avoids parameters that would lead to the scan track defects, it cannot fully predict phenomena associated with the layer-by-layer scanning typical of the PBF-LB/M production, as demonstrated by Martucci et al [ 62 ].…”

Section: Pre-processingmentioning

confidence: 99%

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Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

2023

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Their high strength-to-weight ratio, good corrosion resistance and excellent thermal and electrical conductivity have exponentially increased the interest in aluminium alloys in the context of laser-based powder bed fusion (PBF-LB/M) production. Although Al-based alloys are the third most investigated category of alloys in the literature and the second most used in industry, their processing by PBF-LB/M is often hampered by their considerable solidification shrinkage, tendency to oxidation, high laser reflectivity and poor powder flowability. For these reasons, high-strength Al-based alloys traditionally processed by conventional procedures have often proved to be unprintable with additive technology, so the design and development of new tailored Al-based alloys for PBF-LB/M production is necessary. The aim of the present work is to explore all the challenges encountered before, during and after the PBF-LB/M processing of Al-based alloys, in order to critically analyse the solutions proposed in the literature and suggest new approaches for addressing unsolved problems. The analysis covers the critical aspects in the literature as well as industrial needs, industrial patents published to date and possible future developments in the additive market.

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Section: Pre-processingmentioning

confidence: 99%

Section: Pre-processingmentioning

confidence: 99%

Section: Pre-processingmentioning

confidence: 99%

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Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

2023

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“…Among the techniques used in DOE projects, full factorial design 2 n stands out in defining the main parameters that influence the process in order to evaluate their effects on the response variable by testing all combinations between levels of the variables, covering all the experimental possibilities [36,38].…”

Section: Introductionmentioning

confidence: 99%

Influence of ball milling parameters on microstructure and magnetic properties of aluminum bronze chips reinforced with vanadium carbide

Dias

Silva

2021

Int J Adv Manuf Technol

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This article analyzes the influence of mechanical ball milling parameters on processed aluminum bronze chips in order to increase the efficiency of this process in terms of particles' size reduction. Also evaluated is the addition of vanadium carbide (VC) in this response, along with its microstructure and magnetic properties. The experiments have been carried out in accordance with DOE design methodology. After machined, its residues can still be reused to produce composites through powder metallurgy routes, preserving good mechanical properties without onus to the environment. The study aims to produce and characterize powders resulting from ball milling processes, identifying the influential parameters, in addition to verify its soft magnetization behavior. The powder morphologies and particle sizes underwent scanning electron microscopy (SEM), coupled with energy-dispersive spectroscopy (EDS) and laser diffraction particle analyses, respectively, in addition to phase identification via X-ray diffraction (XRD). Moreover, saturation magnetization (M s ), remanent magnetization (M r ), coercivity (H c ), and remanence-to-saturation ratio (M r /M s ) were determined through magnetic hysteresis curves obtained from a vibrating sample magnetometer (VSM). Results indicate that % VC and milling time are the main parameters to improve the milling efficiency and obtain submicrometric particles with sizes almost 800 times smaller than the initial chips. After the milling process, aluminum bronze powders presented certain amorphization, a decrease of about 24% in M s and an elevation about 81% in H c , both compared with the as cast material. The M r /M s ratio indicates a slight conservation of magnetization.

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“…Сплавы системы Al-Si близкие к эвтектическому составу используются для изготовления отливок сложной формы. Но сплавы системы Al-Si имеют грубую игольчатую эвтектику в обычных отливках, что значительно ухудшает механические свойства[2,3]. В литейных сплавах Al-Si является наличие примеси Fe, которая может образовывать длинную игольчатую фазу β-AlFeSi[2,3].…”

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Structure of Thin-Wall Ak12 Alloy Products Produced by Wire Electron-Beam Additive Manufacturing

Utyaganova¹,

Shamarin²,

Filippov³

et al. 2022

Physical Mesomechanics of Materials. Physical Principles of Multi-Layer Structure Forming and Mechanisms of Non-Linear Behavior

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Efficient optimization methodology for laser powder bed fusion parameters to manufacture dense and mechanically sound parts validated on AlSi12 alloy

Cited by 27 publications

References 40 publications

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review

Influence of ball milling parameters on microstructure and magnetic properties of aluminum bronze chips reinforced with vanadium carbide

Structure of Thin-Wall Ak12 Alloy Products Produced by Wire Electron-Beam Additive Manufacturing

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