Hole design quality identification in laser aided additive manufacturing

Ahn, Il Hyuk; Moon, Seung Ki; Bi, Guijun

doi:10.1177/0954405416657584

Cited by 7 publications

(6 citation statements)

References 26 publications

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“…4–6 Nevertheless, without a set of optimal parameters, many holes, cracks, and other defects than can be tolerated may form in the cladding layer. 7–9 Furthermore, Invar alloys contain a high amount of Ni, and the liquid metal fluidity of the molten pool is poor. These factors may lead to low strength and high residual stress between the cladding layer and the base material.…”

Section: Introductionmentioning

confidence: 99%

Parameter optimisation of laser cladding repair for an Invar alloy mould

Zhu

Chen

Zhan

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part B:

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Laser cladding repair is an advanced technology for repairing Invar alloy moulds; however, the influences of various processing parameters on the quality of the Invar alloy moulds have yet to be determined. To explore the optimisation of laser cladding repair parameters, analyses of the geometric features and microstructure of the cladding layer were conducted. First, the influences of different powder feeding rates and scanning speeds on the dilution rate of the substrate were investigated by establishing a mathematical model of the laser power attenuation. Next, the influences of the parameters on the geometric features of the cladding layer were analysed. Finally, the influences of the parameters on the microstructure of the cladding layer were evaluated. At a laser power of 2300 W, a scanning speed of 3 m/min, and a powder feeding rate of 9 g/min, the best results of the width, height, dilution rate, roughness, and contact angle of the cladding layer were obtained. The results of this study indicated that excellent metallurgical bonding occurred between the cladding layer and the interface layer, and that the intended geometric features and desired microstructure of the cladding layer were obtained.

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Section: Introductionmentioning

confidence: 99%

Parameter optimisation of laser cladding repair for an Invar alloy mould

Zhu

Chen

Zhan

et al. 2018

Proceedings of the Institution of Mechanical Engineers, Part B:

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“…The minimum point support structures, 29 ''Y,'' ''IY,'' and pin support structure 30 were also applied in the SLM process to balance a tradeoff between the build consumption and the effectiveness and easiness of removal of the designed support structure. Other factors, including part geometry like chord height tolerance and diameter of holes, 31 part placement, 32 post-machining condition, 33 were also proposed to influence the quality of the final products by affecting geometric accuracy and inherent residual stress.…”

Section: E = Pmentioning

confidence: 99%

Investigation of significant factors on deformation with powder bed fusion system

Pan

Zhang

et al. 2020

Proceedings of the Institution of Mechanical Engineers, Part B:

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Powder bed fusion (PBF) is one of the most popular techniques in additive manufacturing (AM). The PBF technique of selective laser melting (SLM) consolidates powder layer by layer using a laser as the energy source. This technique ensures the processes capability of fabricating components with internal and external complex geometries, which could be challenging to make with conventional manufacturing methods. However, the cyclic heating and cooling inherent in this process give rise to the buildup of residual stresses, which can distort or completely deform the part. In this work, a screening build with nine factors was designed to investigate the effects of component size, support structure, and energy input on the build completion and average distortion induced by the inherent residual stress. Experimental results indicated that support hatch spacing, part thickness, and support contact spacing played dominant roles in the final quality (i.e. resultant deformation) of the built parts. The identified significant factors from this study can be carefully selected to increase the success rates of single builds and improve the qualities (i.e. geometric accuracy) of the final products.

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“…Mathematical methodology is usually adopted to relate input variables and desired responses so as to quantify the output parameters. In a laser-aided AM study by Ahn et al, 44 a relationship has been established between the input variables, such as chord height tolerance and hole diameter, and response such as geometric error, for the purpose of evaluating the geometric accuracy of 3D printed parts with hole features. In this research, it has been noted that material properties have a rather complex effect on the melt pool geometry in the EBAM process.…”

Section: Design-of-experiments Approachmentioning

confidence: 99%

A numerical investigation of thermal property effects on melt pool characteristics in powder-bed electron beam additive manufacturing

Cheng

Chou

2016

Proceedings of the Institution of Mechanical Engineers, Part B:

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Powder-bed electron beam additive manufacturing has the potential to be a cost-effective alternative in producing complex-shaped, custom-designed metal parts using various alloys. Material thermal properties have a rather sophisticated effect on the thermal characteristics such as the melt pool geometry in fabrications, impacting the build part quality. The objective of this study is to achieve a quantitative relationship that can correlate the material thermal properties and the melt pool geometric characteristics in the electron beam additive manufacturing process. The motivation is to understand the interactions of material property effect since testing individual properties is insufficient because of the change of almost all thermal properties when switching from one to the other material. In this research, a full-factorial simulation experiment was conducted to include a wide range of the thermal properties and their combinations. A developed finite element thermal model was applied to perform electron beam additive manufacturing process thermal simulations incorporating tested thermal properties. The analysis of variance method was utilized to evaluate different thermal property effects on the simulated melt pool geometry. The major results are summarized as follows. (1) The material melting point is the most dominant factor to the melt pool size. (2) The role of the material thermal conductivity may outweigh the melting point and strongly affects the melt pool size, if the thermal conductivity is very high. (3) Regression equations to correlate the material properties and the melt pool dimension and shape have been established, and the regressionpredicted results show a reasonable agreement with the simulation results for tested real-world materials. However, errors still exist for materials with a small melt pool such as copper.

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Hole design quality identification in laser aided additive manufacturing

Cited by 7 publications

References 26 publications

Parameter optimisation of laser cladding repair for an Invar alloy mould

Parameter optimisation of laser cladding repair for an Invar alloy mould

Investigation of significant factors on deformation with powder bed fusion system

A numerical investigation of thermal property effects on melt pool characteristics in powder-bed electron beam additive manufacturing

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