Influence of scan strategy and process parameters on microstructure and its optimization in additively manufactured nickel alloy 625 via laser powder bed fusion

Arısoy, Yiğit M.; Criales, Luis E.; Özel, Tuğrul; Lane, Brandon; Moylan, Shawn P.; Dönmez, Alkan

doi:10.1007/s00170-016-9429-z

Cited by 145 publications

(67 citation statements)

References 19 publications

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“…Concurrent optimization of MAM process variables and a part's topology therefore has the potential to further reduce the production costs. While the potential to optimize AM process parameters and part topology has been discussed in the literature [18,19] and empirical case studies have been presented to optimize process parameters given a fixed topology [20][21][22][23][24][25], no previous literature has concurrently optimized a part's topology as well as process variables. Moreover, no existing methodologies have been developed to minimize total production costs in a topology optimization, which, as we discuss, can lead to significantly different part designs than the standard topology optimization formulation.…”

Section: Introductionmentioning

confidence: 99%

Concurrent Structure and Process Optimization for Minimum Cost Metal Additive Manufacturing

Ulu

Huang

Kara

et al. 2019

Journal of Mechanical Design

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Metals-additive manufacturing (MAM) is enabling unprecedented design freedom and the ability to produce significantly lighter weight parts with the same performance, offering the possibility of significant environmental and economic benefits in many different industries. However, the total production costs of MAM will need to be reduced substantially before it will be widely adopted across the manufacturing sector. Current topology optimization approaches focus on reducing total material volume as a means of reducing material costs, but they do not account for other production costs that are influenced by a part's structure such as machine time and scrap. Moreover, concurrently optimizing MAM process variables with a part's structure has the potential to further reduce production costs. This paper demonstrates an approach to use process-based cost modeling (PBCM) in MAM topology optimization to minimize total production costs, including material, labor, energy, and machine costs, using cost estimates from industrial MAM operations. The approach is demonstrated on various 3D geometries for the electron beam melting (EBM) process with Ti64 material. Concurrent optimization of the part structures and EBM process variables is compared to sequential optimization, and to optimization of the structure alone. The results indicate that, once process variables are considered concurrently, more cost effective results can be obtained with similar amount of material through a combination of (1) building high stress regions with lower power values to obtain larger yield strength and (2) increasing the power elsewhere to reduce the number of passes required, thereby reducing build time. In our case studies, concurrent optimization of the part's structure and MAM process parameters lead to up to 15% lower estimated total production costs and 21% faster build time than optimizing the part's structure alone.

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Section: Introductionmentioning

confidence: 99%

Concurrent Structure and Process Optimization for Minimum Cost Metal Additive Manufacturing

Ulu

Huang

Kara

et al. 2019

Journal of Mechanical Design

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“…The substructure appeared to be cells or corrugations in the etched two-dimensional (2D) section, and was believed to exist everywhere in the bulk sample [4][5][6]. Some researchers realized that the substructure had a three-dimensional (3D) morphology [7,8], which was in the form of a prismatic array [9]. Nevertheless, the 3D morphology of the substructure has seldom been validated [10].…”

Section: Introductionmentioning

confidence: 99%

“…The general method to study the substructure can be based on the etched 2D morphology [2][3][4][5][6][7][8]10,11], which is cheap, easy to operate and effective. However, the 3D information on the growth direction of the substructure cannot be obtained directly from the 2D morphology.…”

Section: Introductionmentioning

confidence: 99%

“…Chen et al built a model of hexagonal prism to analyze the angle between the growth direction and the normal direction of the 2D section [7]. Arısoy et al studied the angle of the growth direction to the building direction [8].…”

Section: Introductionmentioning

confidence: 99%

“…These studies only took one angle into account [7,8], while three angles are necessary to specify a unique direction in 3D [12]. Hitherto, there is a lack of research to construct the substructure from the 2D morphology in consideration of three angles.…”

Section: Introductionmentioning

confidence: 99%

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Construction of Cellular Substructure in Laser Powder Bed Fusion

Wang

Zhang

et al. 2019

Metals

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Cellular substructure has been widely observed in the sample fabricated by laser powder bed fusion, while its growth direction and the crystallographic orientation have seldom been studied. This research tries to build a general model to construct the substructure from its two-dimensional morphology. All the three Bunge Euler angles to specify a unique growth direction are determined, and the crystallographic orientation corresponding to the growth direction is also obtained. Based on the crystallographic orientation, the substructure in the single track of austenitic stainless steel 316L is distinguished between the cell-like dendrite and the cell. It is found that, with the increase of scanning velocity, the substructure transits from cell-like dendrite to cell. When the power is 200 W, the critical growth rate of the transition in the single track can be around 0.31 ms−1.

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Thermokinetics, Microstructural Evolution, and Material Response

2022

Laser‐Based Additive Manufacturing

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Influence of scan strategy and process parameters on microstructure and its optimization in additively manufactured nickel alloy 625 via laser powder bed fusion

Cited by 145 publications

References 19 publications

Concurrent Structure and Process Optimization for Minimum Cost Metal Additive Manufacturing

Concurrent Structure and Process Optimization for Minimum Cost Metal Additive Manufacturing

Construction of Cellular Substructure in Laser Powder Bed Fusion

Thermokinetics, Microstructural Evolution, and Material Response

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