Investigation of Mechanical Properties of Parts Fabricated with Gas- and Water-Atomized 304L Stainless Steel Powder in the Laser Powder Bed Fusion Process

Sehhat, M. Hossein; Sutton, Austin T.; Hung, Chia-Hung; Newkirk, Joseph William; Leu, Ming C.

doi:10.1007/s11837-021-05029-7

Cited by 26 publications

(9 citation statements)

References 21 publications

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“…As for mechanical performance, the YS and UTS of the 316L stainless steel parts printed by the water-atomized powders are slightly lower than that of the gas-atomized powders, but the difference in the elongation and hardness is marginal [96,97]. Similarly, the YS (470 MPa), UTS (674 MPa), and elongation (29%) of the 304L stainless steel samples based on the water-atomized powders are lower than those of the gas-atomized counterparts (YS of 507 MPa, UTS of 688 MPa, and elongation of 69%) [100]. In contrast, Cacace and Semeraro [99] found that the mechanical properties were comparable for L-PBF samples printed with gas-atomized and water-atomized 316L stainless steel powders.…”

Section: Wamentioning

confidence: 88%

“…In this section, the preparation principles, advantages, and limitations of the above-mentioned powder preparation methods are described in turn. In addition, the mechanical properties of L-PBF parts with powders fabricated via different preparation methods are also compared, including the Ti6Al4V powders prepared by GA, EIGA, PA, and PREP [81][82][83][84][85][86][87][88][89], AlSi10Mg powders prepared by GA and PA [20,[90][91][92][93], Inconel 718 powders produced by GA and PREP [94,95], 316L stainless steel powders fabricated by GA, VIGA, and WA [96][97][98][99], and 304L stainless steel powders yielded by GA and WA [100].…”

Section: Powder Preparation Methodsmentioning

confidence: 99%

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Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Sun,

Chen,

Liu

et al. 2023

Int. J. Extrem. Manuf.

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Laser powder bed fusion (L-PBF) has attracted significant attention since its inception, providing unprecedented advantages to fabricate metallic components with complex geometry. The quality and performance of as-printed alloys is an intricate function consisting of numerous factors linking the feedstock powders, manufacturing, and post-treatment. As the starting materials, powders play a critical role in influencing the printing consistency, total fabrication cost, and mechanical properties. In consideration of its importance for L-PBF, the present review aims to review the recent progress on metallic powders for L-PBF focusing on powder characterization, powder fabrication, and powder reuse. The methods of powder characterization and fabrication were presented in the beginning by analyzing the principles and corresponding advantages and limitations. Subsequently, the effect of powder reuse on the powder characteristics and mechanical performance of L-PBF parts is analyzed focusing on steels, nickel-based superalloys, Ti and Ti alloys, and Al alloys. The evolution trend of powders and as-printed parts varies for different alloy systems based on the existing studies, which makes the proposal of a unified reuse protocol infeasible. Finally, perspectives are presented to cater to the increasing applications of AM technologies for future investigations. The present state-of-the-art work can pave the way for the broad industrial applications of L-PBF by enhancing printing consistency and reducing the total cost from the perspective of powders.

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Section: Wamentioning

confidence: 88%

Section: Powder Preparation Methodsmentioning

confidence: 99%

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Sun,

Chen,

Liu

et al. 2023

Int. J. Extrem. Manuf.

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show abstract

“…The ease of manufacture of components produced by Fused Deposition Modeling (FDM) out of Polymers makes them useful for rapid prototyping and scale testing of mechanisms and structures before mass-production or large-scale installation [21,22]. In addition, considering the process impacts on both user-safety and the environment, the lament format of feedstock material to FDM process is less hazardous than the other formats of feedstock, such as powder in powder-based AM processes [23][24][25][26]. Before the advent of affordable FDM technology, prototypes may have been manufactured out of polymers using injection molding, which is both timeconsuming and expensive on smaller scales [27,28].…”

Section: Introductionmentioning

confidence: 99%

Verification of stress transformation in anisotropic material additively manufactured by fused deposition modeling (FDM)

Sehhat

Mahdianikhotbesara

Yadegari

2022

Int J Adv Manuf Technol

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The widespread use of Additive Manufacturing (AM) has been extensively progressed in the past decade due to the convenience provided by AM in rapid and reliable part production. Fused Deposition Modeling (FDM) has witnessed even faster growth of application as its equipment is environmentally-friendly and easily adaptable. This increased use of FDM to manufacture prototypes and nished parts is accompanied by concerns that 3D printed parts do not perform the same as relatively homogeneous parts produced by molding or machining. As the interface between two faces of bonded material may be modeled by stress elements, in theory by modeling 3D printed layers subjected to tension at varying angles as transformed stress elements, the stress required to break the layer bonds can be determined. To evaluate such a relationship, in this study, the stresses calculated from stress transformation were compared with the behavior of 3D printed specimens subjected to tensile loads. The maximum principal stress was found to be constant relative to the layer angle, regardless of whether the specimen experienced failure at the layer interface or within the layer material, although the specimens with layers 75° relative to the load were notable exceptions to this nding. This failure at much lower stresses for the samples used in the 75° tests may be attributed to a possible environmental factor, such as temperature or humidity change, degrading the samples' structural integrity.

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“…The powder feedstock needs to have su cient owability in order to ensure that the powder adequately spreads along the build plate during the EB-PBF process. The more spherical particle geometries result in better owability and powder packing which consequently increases the powder bed density and improves the properties of fabricated parts [34][35][36][37]. Therefore, the powder feedstock to the EB-PBF process is recommended to be provided in spherical geometries.…”

Section: Introductionmentioning

confidence: 99%

Characterization of Virgin, Recycled, and Oxygen-reduced Copper Powders Processed by the Plasma Spheroidization

Sehhat

Cullom

Newkirk

2022

Preprint

Self Cite

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Copper powder in three different powder types were spheroidized using radio-frequency inductively coupled plasma (ICP) spheroidization process (TekSphero-15 system). The characterized powders include virgin powder as purchased from the powder manufacturer, powder used in electron beam powder bed fusion (EB-PBF) process, and reconditioned powder, which was used powder that underwent an oxygen-reduction treatment. The goal of spheroidizing these powder types was to evaluate the change in powder morphology, the possibility of enhancing the powder properties back to their as-received conditions, and assess oxygen reduction of the powder lots given their initial oxygen contents. Also, to investigate the impact of re-spheroidization on powder properties, the second round of spheroidization was performed on the already used-spheroidized powder. The impact of powder type on powder sphericity and particle size distribution was evaluated using the image analysis of scanning electron microscope (SEM) micrographs and laser diffraction, respectively. The spheroidized powder showed higher sphericity and more uniform particle size distribution overall. Depending on the powder collection bin, second round of spheroidization affected the powder sphericity differently. The possibility of deploying the plasma spheroidization process as an alternative oxygen-reduction technique was also investigated through tracking the powders’ oxygen content using inert gas fusion method before and after the spheroidization. The plasma spheroidized powder showed less oxygen content than the hydrogen-treated powder. The second round of spheroidization caused no change in oxygen content. The correlation between oxygen-reduction and created cracks was discussed and compared between plasma spheroidization and hydrogen-treatment. The plasma spheroidization process created a powder with higher sphericity, uniform particle size, and less oxygen content.

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Investigation of Mechanical Properties of Parts Fabricated with Gas- and Water-Atomized 304L Stainless Steel Powder in the Laser Powder Bed Fusion Process

Cited by 26 publications

References 21 publications

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Verification of stress transformation in anisotropic material additively manufactured by fused deposition modeling (FDM)

Characterization of Virgin, Recycled, and Oxygen-reduced Copper Powders Processed by the Plasma Spheroidization

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