Laser-arc hybrid additive manufacturing of stainless steel with beam oscillation

Gong, Mengcheng; Meng, Yunfei; Zhang, Shuai; Zhang, Yazhou; Zeng, Xiaoyan; Gao, Ming

doi:10.1016/j.addma.2020.101180

Cited by 38 publications

(26 citation statements)

References 29 publications

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“…Laser technology has been widely used in different industrial processes for many years, due to the characteristics of the laser source: high energy density, high efficiency, large temperature gradients, high repeatability of the process, and formation of a narrow heat-affected zone (HAZ) [1]. Nowadays, it is possible to find various research works on laser technologies such as laser welding [2,3], cutting [4,5], remelting [6,7], additive technologies [8,9] . .…”

Section: Introductionmentioning

confidence: 99%

The Effect of the Laser Incidence Angle in the Surface of L-PBF Processed Parts

Sendino¹,

Gardon²,

Lartategui

et al. 2020

Coatings

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The manufacture of multiple parts on the same platform is a common procedure in the Laser Powder Bed Fusion (L-PBF) process. The main advantage is that the entire working volume of the machine is used and a greater number of parts are obtained, thus reducing inert gas volume, raw powder consumption, and manufacturing time. However, one of the main disadvantages of this method is the possible differences in quality and surface finish of the different parts manufactured on the same platform depending on their orientation and location, even if they are manufactured with the same process parameters and raw powder material. Throughout this study, these surface quality differences were studied, focusing on the variation of the surface roughness with the angle of incidence of the laser with respect to the platform. First, a characterization test was carried out to understand the behavior of the laser in the different areas of the platform. Then, the surface roughness, microstructure, and minimum thickness of vertical walls were analyzed in the different areas of the platform. These results were related to the angle of incidence of the laser. As it was observed, the laser is completely perpendicular only in the center of the platform, whilst at the border of the platform, due to the incidence angle, it melts an elliptical area, which affects the roughness and thickness of the manufactured part. The roughness increases from values of Sa = 5.489 μm in the central part of the platform to 27.473 μm at the outer borders while the thickness of the manufactured thin walls increases around 40 μm.

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Section: Introductionmentioning

confidence: 99%

The Effect of the Laser Incidence Angle in the Surface of L-PBF Processed Parts

Sendino¹,

Gardon²,

Lartategui

et al. 2020

Coatings

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show abstract

“…A low-power laser beam assists the build process and improves process performance and part quality. The energy density of the plasma arc can be improved, and the plasma arc diameter favorably decreased, which enhances the accuracy of the part (Wang et al, 2014;Gong et al, 2020;Wang et al, 2021b). At the same time, arc igniting became easier because of plasma induced by the laser.…”

Section: Tungsten Inert Gas/plasma-laser Hybrid-depositionmentioning

confidence: 99%

“…• 20% improvement in surface roughness Gong et al (2020) • 34% improvement in the elongation along with reduced anisotropy. The yield strength has been reported to be enhanced by 15%…”

Section: Conformal + Horizontalmentioning

confidence: 99%

Hybridization in wire arc additive manufacturing

2022

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Wire Arc Additive Manufacturing (WAAM) can produce a near-net shape of an object within a short period due to its capability of high deposition rate compared with other metal Additive Manufacturing (AM) processes. The recent developments in the WAAM have increased its efficiency and cost-effectiveness in producing viable products. However, poor surface quality, porosities, residual stresses, distortions, and anisotropic mechanical properties are a few inherent challenges still associated with the WAAM, which necessitates the hybridization of this process. Hybrid-WAAM is a synergic integration of one or more deposition processes, manufacturing processes, layering strategies, raw stock materials, and machine tool kinematics that are fully coupled and affect part quality, functionality, and process performance. This paper comprehensively reviews different levels of hybridization in the WAAM to eliminate its associated challenges. These levels of hybridizations are classified into five categories: hybrid-deposition processes, hybrid-manufacturing processes, hybrid-layering strategies, hybrid-machine tools, and hybrid-raw stock. Furthermore, these levels of hybridization are mapped to eliminate the associated defects/challenges in the WAAM, which will help the readers select an appropriate level of hybridization.

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“…Gong. et al introduced an oscillating laser beam in the LHAM of stainless steel to solve this problem, and they found that the beam oscillation behavior was able to reduce the surface roughness by 20%, to increase the deposition efficiency by 4 times compared to WAAM, and significantly to reduce the internal porosity of the part [21]. Oscillating laser-arc hybrid additive manufacturing(O-LHAM) has a very positive effect on improving the quality of components.…”

Section: Introductionmentioning

confidence: 99%

Oscillating laser-arc hybrid additive manufacturing of AZ31 magnesium alloy

Cen

Gong

Gao

2022

Advanced Laser Processing and Manufacturing VI

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Laser-arc hybrid additive manufacturing with beam oscillation (O-LHAM) was introduced to fabricate AZ31 magnesium alloy thin-wall components. The effect of the beam oscillating frequency on the morphological characteristics, internal porosity, microstructure, and mechanical properties was investigated. It was found that increasing oscillating frequency is effective to suppress the imperfections of lack of fusion, height differences, and wavy hump, as well as the number and size of internal porosity. The beam oscillation was beneficial to fragmentizing the average grain size and promoting the precipitation of Al8Mn5 and Mg17Al12 phases by generating stirring laminar flow in the molten pool, and it can disrupt the grain structure and provide more nucleation sites. Compared to the case without beam oscillation, the average grain size range decreased from 22-32 μm to 18-20 μm when the frequency increases to 300 Hz, while the precipitation percentage increased from 1.42-1.61% to 2.55-3.32%. For the components without porosity detected by the X-ray nondestructive test, the ultimate tensile strength and the elongation were 205 MPa and 20.7%, respectively, which are higher than those of AZ31 cast magnesium alloy. The tensile fracture has characterized the dimples with a small part of ductile tearing ridges, showing good ductility. The results indicated that O-LHAM would be effective to solve the tough problems in deposition quality and efficiency of additively manufactured Mg alloys.

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Laser-arc hybrid additive manufacturing of stainless steel with beam oscillation

Cited by 38 publications

References 29 publications

The Effect of the Laser Incidence Angle in the Surface of L-PBF Processed Parts

The Effect of the Laser Incidence Angle in the Surface of L-PBF Processed Parts

Hybridization in wire arc additive manufacturing

Oscillating laser-arc hybrid additive manufacturing of AZ31 magnesium alloy

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