Enhanced structural integrity of Laser Powder Bed Fusion based AlSi10Mg parts by attaining defect free melt pool formations

Kumar, M. Saravana; Yang, Che-Hua; Farooq, Muhammad Umar; Kavimani, V.; Adesoji, Adediran Adeolu

doi:10.1038/s41598-023-43718-2

Cited by 10 publications

(3 citation statements)

References 50 publications

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“…BBD employed in this study follows a three-level factorial design approach, where the factors under investigation are examined at low, medium, and high levels 67 , 68 . This design is constructed using a series of points that form a three-level factorial design, which is then augmented with additional points forming a central composite design.…”

Section: Methodsmentioning

confidence: 99%

Ironing process optimization for enhanced properties in material extrusion technology using Box–Behnken Design

Alzyod,

Ficzere

2024

Sci Rep

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Material Extrusion (MEX) technology, a prominent process in the field of additive manufacturing (AM), has witnessed significant growth in recent years. The continuous quest for enhanced material properties and refined surface quality has led to the exploration of post-processing techniques. In this study, we delve into the ironing process as a vital processing step, focusing on the optimization of its parameters through the application of Design of Experiments (DoE), specifically the Box–Behnken Design (BBD). Through a systematic examination of ironing process parameters, we identified optimal conditions that resulted in a substantial reduction in surface roughness (Ra) by approximately 69%. Moreover, the integration of optimized ironing process parameters led to remarkable improvements in mechanical properties. For instance, the Ultimate Tensile Strength (UTS) saw a substantial improvement of approximately 29%, while the compressive strength (CS) showed an increase of about 25%. The flexural strength (FS) witnessed a notable enhancement of around 35%, and the impact strength (IS) experienced a significant boost of about 162%. The introduction of ironing minimizes voids, enhances layer bonding, and reduces surface irregularities, resulting in components that not only exhibit exceptional mechanical performance but also possess refined aesthetics. This research sheds light on the transformative potential of precision experimentation, post-processing techniques, and statistical methodologies in advancing Material Extrusion technology. The findings offer practical implications for industries requiring high-performance components with structural integrity and aesthetic appeal.

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Section: Methodsmentioning

confidence: 99%

Ironing process optimization for enhanced properties in material extrusion technology using Box–Behnken Design

Alzyod,

Ficzere

2024

Sci Rep

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“…Chu [ 21 ] confirmed that coarser powders are much more sensitive to changes in laser power in terms of melt pool characteristics, defect population, and size, showing significant improvements in relative density upon increasing laser power. Kumar [ 22 ] obtained optimal process parameters such as laser power, scanning speed, layer thickness, and hatch spacing, improving the structural integrity of the printed AlSi10Mg parts. Chen [ 23 ] proposed a novel approach in order to reduce defects, refine grains, and enhance hardness during the LPBF process, utilizing low laser power and a continuous scanning strategy.…”

Section: Introductionmentioning

confidence: 99%

Process Optimization of SiC-Reinforced Aluminum Matrix Composites Prepared Using Laser Powder Bed Fusion and the Effect of Particle Morphology on Performance

Ji,

Li,

Liu

et al. 2024

Materials

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Process parameters and powder spreading quality are important factors for aluminum matrix composites (AMCs) prepared using laser powder bed fusion (LPBF). In this study, a Box–Behnken Design (BBD) was used to optimize the process parameters, and near-spherical β-SiC was selected to improve the quality of powder spreading. The rationality of parameter optimization was verified by testing the density of samples prepared using different laser power levels. Al4C3 diffraction peaks were found in XRD patterns, which indicated that interface reactions occurred to form good interface bonding between the Al matrix and the SiC particles. The tensile strength and plasticity of LPBF α-SiC/AlSi10Mg were lower than that of LPBF AlSi10Mg, which was mainly due to the poor fluidity of the powder mixtures and powder spreading quality. For LPBF β-SiC/AlSi10Mg, the tensile strength increased and elongation decreased slightly compared to LPBF α-SiC/AlSi10Mg. The data in this study were compared with the data in other studies. In this study, LPBF AlSi10Mg and LPBF β-SiC/AlSi10Mg not only showed the inherent high strength of their LPBF parts, but also had relatively high plasticity. Matching between strength and plasticity was mainly dependent on the scanning strategy. Most studies use uni-directional or bi-directional scanning strategies with a certain rotation angle between layers. A chessboard scanning strategy was used in this study to form a coarse remelted connected skeleton inside the material and significantly improve plasticity. This study lays a theoretical and experimental foundation for the controllable preparation of SiC-reinforced AMCs using LPBF.

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“…One of the common defects observed in metallic components subjected to fatigue loading during service is cracking [18,19]. These cracks cannot simply be filled with additive feedstock material.…”

Section: Introductionmentioning

confidence: 99%

Effect of Pre-Heating on Residual Stresses and Deformation in Laser-Based Directed Energy Deposition Repair: A Comparative Analysis

Tariq,

Wu,

Mahmood

et al. 2024

Materials

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Laser-directed energy deposition (DED), a metal additive manufacturing method, is renowned for its role in repairing parts, particularly when replacement costs are prohibitive. Ensuring that repaired parts avoid residual stresses and deformation is crucial for maintaining functional integrity. This study conducts experimental and numerical analyses on trapezoidal shape repairs, validating both the thermal and mechanical models with experimental results. Additionally, the study presents a methodology for creating a toolpath applicable to both the DED process and Abaqus CAE software. The findings indicate that employing a pre-heating strategy can reduce residual stresses by over 70% compared to no pre-heating. However, pre-heating may not substantially reduce final distortion. Notably, final distortion can be significantly mitigated by pre-heating and subsequently cooling to higher temperatures, thereby reducing the cooling rate. These insights contribute to optimizing DED repair processes for enhanced part functionality and longevity.

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Enhanced structural integrity of Laser Powder Bed Fusion based AlSi10Mg parts by attaining defect free melt pool formations

Cited by 10 publications

References 50 publications

Ironing process optimization for enhanced properties in material extrusion technology using Box–Behnken Design

Ironing process optimization for enhanced properties in material extrusion technology using Box–Behnken Design

Process Optimization of SiC-Reinforced Aluminum Matrix Composites Prepared Using Laser Powder Bed Fusion and the Effect of Particle Morphology on Performance

Effect of Pre-Heating on Residual Stresses and Deformation in Laser-Based Directed Energy Deposition Repair: A Comparative Analysis

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