Influence of metal powder cross-contaminations on part quality in Laser Powder Bed Fusion: copper alloy particles in maraging steel feedstock

Horn, Max; Langer, L.; Schafnitzel, Mario; Dietrich, Simone; Schlick, Georg; Seidel, Christian; Reinhart, Gunther

doi:10.1016/j.procir.2020.09.032

Cited by 17 publications

(12 citation statements)

References 16 publications

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“…The post-process also includes the reconditioning of unsolidified powder material, since cross-contaminations cannot be fully avoided during the MM PBF in-process. Because remaining foreign particles can lead to inferior material properties, the powder materials need to be sorted before their reuse [74]. Contamination levels arising during the in-process depend on the facilitated deposition device and have not been studied for every concept.…”

Section: Post-process: Powder Separation and Part Finalizationmentioning

confidence: 99%

Review on additive hybrid- and multi-material-manufacturing of metals by powder bed fusion: state of technology and development potential

et al. 2021

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In this review paper, the authors investigate the state of technology for hybrid- and multi-material (MM) manufacturing of metals utilizing additive manufacturing, in particular powder bed fusion processes. The study consists of three parts, covering the material combinations, the MM deposition devices, and the implications in the process chain. The material analysis is clustered into 2D- and 3D-MM approaches. Based on the reviewed literature, the most utilized material combination is steel-copper, followed by fusing dissimilar steels. Second, the MM deposition devices are categorized into holohedral, nozzle-based as well as masked deposition concepts, and compared in terms of powder deposition rate, resolution, and manufacturing readiness level (MRL). As a third aspect, the implications in the process chain are investigated. Therefore, the design of MM parts and the data preparation for the production process are analyzed. Moreover, aspects for the reuse of powder and finalization of MM parts are discussed. Considering the design of MM parts, there are theoretical approaches, but specific parameter studies or use cases are not present in the literature. Principles for powder separation are identified for exemplary material combinations, but results for further finalization steps of MM parts have not been found. In conclusion, 3D-MM manufacturing has a MRL of 4–5, which indicates that the technology can be produced in a laboratory environment. According to this maturity, several aspects for serial MM parts need to be developed, but the potential of the technology has been demonstrated. Thus, the next important step is to identify lead applications, which benefit from MM manufacturing and hence foster the industrialization of these processes.

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Section: Post-process: Powder Separation and Part Finalizationmentioning

confidence: 99%

Review on additive hybrid- and multi-material-manufacturing of metals by powder bed fusion: state of technology and development potential

et al. 2021

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“…Furthermore, the accumulation of liquefied copper along the already solidified grain boundaries of the steel materials can lead to hot cracking [20,21,24,25]. This has also been shown in PBF-LB/M for tool steel 1.2709 contaminated with copper alloy particles [26].…”

Section: Introductionmentioning

confidence: 71%

“…Results indicate that higher material purity was achieved for the copper regions. The steel part of the component contained Cu alloy contamination above the purity threshold described by Horn et al to secure material integrity [26]. Since most defects appeared to be related to imperfect material deposition, the level of cross-contamination was approximated by quantitative EDS analysis (see Table 2).…”

mentioning

confidence: 99%

Capability of Multi-Material Laser-Based Powder Bed Fusion—Development and Analysis of a Prototype Large Bore Engine Component

Schneck

Horn

Schindler

et al. 2021

Metals

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Additive Manufacturing (AM) allows the manufacturing of functionally graded materials (FGM). This includes compositional grading, which enables the allocation of desired materials corresponding to local product requirements. An upcoming AM process for the creation of metal-based FGMs is laser-based powder bed fusion (PBF-LB/M) utilized for multi-material manufacturing (MM). Three-dimensional multi-material approaches for PBF-LB/M are stated to have a manufacturing readiness level (MRL) of 4 to 5. In this paper, an advancement of multi-material technology is presented by realizing an industry-relevant complex part as a prototype made by PBF-LB/M. Hence, a multi-material injection nozzle consisting of tool steel and a copper alloy was manufactured in a continuous PBF-LB/M process. Single material regions showed qualities similar to the ones resulting from mono-material processes. A geometrically defined transition zone between the two materials was achieved that showed slightly higher porosity than mono-material regions. Nevertheless, defects such as porosity, cracks, and material cross-contamination were detected and must be overcome in further MM technology development.

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“…Most of the currently available L-PBF systems only allow the incorporation of a single powder handling system during manufacturing. Multiple powder handling systems might provide problems in terms of powder contamination and may not always be the best option [38]. As a result, it is always recommended to utilize the same powder material for both the component and the support structure.…”

Section: Support Structure Design Optimization and Support Removal Strategiesmentioning

confidence: 99%

An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents

et al. 2021

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One of the fundamental challenges in L-PBF of filigree geometries, such as aortic stents used in biomedical applications, is the requirement for a robust yet easily removable support structure that allows each component to be successfully fabricated without distortion. To solve this challenge, an integrative experimental approach was attempted in the present study by identifying an optimal support structure design and an optimized support removal strategy for this design. The specimens were manufactured using four different support structure designs based on the geometry exposed to the laser beam during the L-PBF. Support removal procedures included sand blasting (SB), glass bead blasting (GB), and electrochemical polishing (ECP). The two best-performing designs (line and cross) were chosen due to shorter lead times and lower material consumption. As an additional factor that indicates a stable design, the breaking load requirement to remove the support structures was determined. A modified line support with a 145° included angle was shown to be the best support structure design in terms of breaking load, material consumption, and manufacturing time. All three procedures were used to ensure residue-free support removal for this modified line support design, with ECP proving to be the most effective.

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Influence of metal powder cross-contaminations on part quality in Laser Powder Bed Fusion: copper alloy particles in maraging steel feedstock

Cited by 17 publications

References 16 publications

Review on additive hybrid- and multi-material-manufacturing of metals by powder bed fusion: state of technology and development potential

Review on additive hybrid- and multi-material-manufacturing of metals by powder bed fusion: state of technology and development potential

Capability of Multi-Material Laser-Based Powder Bed Fusion—Development and Analysis of a Prototype Large Bore Engine Component

An Integrative Experimental Approach to Design Optimization and Removal Strategies of Supporting Structures Used during L-PBF of SS316L Aortic Stents

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