Enhanced Mathematical Model for Producing Highly Dense Metallic Components through Selective Laser Melting

Estrada-Díaz, Jorge A.; Elı́as-Zúñiga, Alex; Martínez-Romero, Óscar; Olvera-Trejo, Daniel

doi:10.3390/ma14061571

Cited by 12 publications

(6 citation statements)

References 33 publications

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“…In the recent research of Khan et al [32], Estrada-Díaz et al [33] and Estrada-Díaz et al [34], the melt pool depth or density for LPBF-processed samples are predicted with dimensional analysis by applying the Buckingham`s Π -theorem. The relation between melt pool depth, density and crack density is still missing.…”

Section: Dimensional Analysis and Modellingmentioning

confidence: 99%

High power selective laser melting of crack sensitive nickel-base alloy CM247LC, including dimensional analysis and modelling

Gerstgrasser

Cloots²,

Jakob³

et al. 2022

Preprint

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High power parameters with increased scan velocities and beam diameters are investigated, to decrease the production time for crack sensitive alloy CM247LC. Results are compared to crack-free reference LPBF-samples in the low power range. The re-scaling approach for the high power range is based on the constant maximum laser intensity from the reference parameters in the low power range. While keeping the laser power to scan velocity ratio constant, the re-scaling approach, also called “intensity approach”, provides an initial estimation for the laser spot size in the high power range. The investigated cracks from the high power range are identified as “re-melting cracks”. Solidification or hot cracks are not observed, since the crack healing effect for those kinds of cracks still occurs. Furthermore, a melt pool depth range is discovered, where not only solidification cracks can be avoided, but also re-melting cracks, which are resulting from higher laser power inputs. This theory can be proven by further laser spot size optimization, where the melt pool depth comes closer to the mentioned range. The Archimedean density and crack density results, in case of the 600 W power parameter with 2400 mm/s scan velocity and a beam diameter of 164 µm, are close to the one obtained from the reference samples, based on 200 W. With the intensity approach and laser beam diameter optimization, the production time can be reduced by 300%. Based on dimensional analysis, a model, which combines the samples density with the crack density through the melt pool depth, is presented. Six main and two additional process and laser parameters are taken into relation. The result from the model and the measured values from experiments are in agreement. Additionally, the influence of the doubled layer thickness and an increased hatch distance by 50% with varying scan velocities on the Archimedean density and crack density is analysed.

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Section: Dimensional Analysis and Modellingmentioning

confidence: 99%

High power selective laser melting of crack sensitive nickel-base alloy CM247LC, including dimensional analysis and modelling

Gerstgrasser

Cloots²,

Jakob³

et al. 2022

Preprint

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“…Specific heat capacity is the quantification of energy required to increment a material's temperature. Literature values of specific heat capacity for AlSi10Mg additively manufactured alloy vary from about 0.73 J/kg • C to 1.1 J/kg • C, depending on the temperature [27][28][29][30].…”

Section: Specific Heat Capacitymentioning

confidence: 99%

Hybrid Manufacturing of Aluminium Parts Combining Additive and Conventional Technologies—Mechanical and Thermal Properties

Silva

Candiango

Rodrigues

et al. 2022

JMMP

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Metal additive-manufacturing technologies enable the production of complex geometries. However, high manufacturing costs hinder these technologies being employed in some industries. In this sense, a hybrid strategy is presented in this paper, to achieve the best of additive and subtractive technologies, offering economic advantages. AlSi10Mg aluminium powder was deposited on AW-6082 pre-machined substrates and mechanical and thermal properties of these specimens were evaluated considering the application of a stress relief heat treatment. The results were especially good in the compressive mechanical properties and in the thermal properties: compressive properties were improved by up to 27%, and the specific heat capacity and coefficient of thermal expansion were reduced by up to 38%, compared to additively manufactured AlSi10Mg. Therefore, hybrid manufacturing can be a profitable solution (i) in thermal management applications, (ii) when compressive loads are presented, or (iii) to repair damaged parts, providing a circular economy, as presented in a case study of this paper.

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“…In [ 78 ], the temperature profile of the powder layer in the SLM process was calculated by the finite element method in a three-dimensional formulation. The research work [ 79 ] is also devoted to the mathematical modeling of the SLM process (for metal powders). The improved model takes into account laser power, scan speed, thermal conductivity and heat capacity of the powder.…”

Section: Trends and Directions For Further Researchmentioning

confidence: 99%

Review of the Problems of Additive Manufacturing of Nanostructured High-Energy Materials

et al. 2021

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This article dwells upon the additive manufacturing of high-energy materials (HEM) with regards to the problems of this technology’s development. This work is aimed at identifying and describing the main problems currently arising in the use of AM for nanostructured high-energy materials and gives an idea of the valuable opportunities that it provides in the hope of promoting further development in this area. Original approaches are proposed for solving one of the main problems in the production of nanostructured HEM—safety and viscosity reduction of the polymer-nanopowder system. Studies have shown an almost complete degree of deagglomeration of microencapsulated aluminum powders. Such powders have the potential to create new systems for safe 3D printing using high-energy materials.

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Enhanced Mathematical Model for Producing Highly Dense Metallic Components through Selective Laser Melting

Cited by 12 publications

References 33 publications

High power selective laser melting of crack sensitive nickel-base alloy CM247LC, including dimensional analysis and modelling

High power selective laser melting of crack sensitive nickel-base alloy CM247LC, including dimensional analysis and modelling

Hybrid Manufacturing of Aluminium Parts Combining Additive and Conventional Technologies—Mechanical and Thermal Properties

Review of the Problems of Additive Manufacturing of Nanostructured High-Energy Materials

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