Manufacturing of Functionally Graded Porous Products by Selective Laser Sintering

Erdal, Merve; Dağ, Serkan; Jande, Yusufu Abeid Chande; Tekin, C.M.

doi:10.4028/www.scientific.net/msf.631-632.253

Cited by 20 publications

(12 citation statements)

References 3 publications

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“…Besides, the LPBF process has been employed in medical applications for producing customized bioimplants [53][54][55]. Recently, new materials, including metal matrix nanocomposites (MMNCs) [56][57][58] and functionally graded materials (FGMs) [59][60][61], are developed through the LPBF technology.…”

Section: Laser Powder Bed Fusionmentioning

confidence: 99%

A Comprehensive Overview on the Latest Progress in the Additive Manufacturing of Metal Matrix Composites: Potential, Challenges, and Feasible Solutions

Dadkhah

Mosallanejad

Iuliano

et al. 2021

Acta Metall. Sin. (Engl. Lett.)

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Nowadays, as an emerging technology, additive manufacturing (AM) has received numerous attentions from researchers around the world. The method comprises layer-by-layer manufacturing of products according to the 3D CAD models of the objects. Among other things, AM is capable of producing metal matrix composites (MMCs). Hence, plenty of works in the literature are dedicated to developing different types of MMCs through AM processes. Hence, this paper provides a comprehensive overview on the latest research that has been carried out on the development of the powder-based AM manufactured MMCs from a scientific and technological viewpoint, aimed at highlighting the opportunities and challenges of this innovative manufacturing process. For instance, it is documented that AM is not only able to resolve the reinforcement/matrix bonding issues usually faced with during conventional manufacturing of MMCs, but also it is capable of producing functionally graded composites and geometrically complex objects. Furthermore, it provides the opportunity for a uniform distribution of the reinforcing phase in the metallic matrix and is able to produce composites using refractory metals thanks to the local heat source employed in the method. Despite the aforementioned advantages, there are still some challenges needing more attention from the researchers. Rapid cooling nature of the process, significantly different coefficient of expansion of the matrix and reinforcement, processability, and the lack of suitable parameters and standards for the production of defect-free AM MMCs seem to be among the most important issues to deal with in future works.

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Section: Laser Powder Bed Fusionmentioning

confidence: 99%

A Comprehensive Overview on the Latest Progress in the Additive Manufacturing of Metal Matrix Composites: Potential, Challenges, and Feasible Solutions

Dadkhah

Mosallanejad

Iuliano

et al. 2021

Acta Metall. Sin. (Engl. Lett.)

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show abstract

“…91 Process parameter is formed by varying the manufacturing parameters to obtain variable energy densities. 97 Energy density is the ratio of power and beam section. 98 From equation (1) 5,21 by controlling the laser power, scanning speed, hatching speed and layer thickness, the FGM characteristics could be formed…”

Section: Design Of Glsmentioning

confidence: 99%

A review on integration of lightweight gradient lattice structures in additive manufacturing parts

Seharing

Azman

Abdullah

2014

Advances in Mechanical Engineering

164

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This review analyses the design, mechanical behaviors, manufacturability, and application of gradient lattice structures manufactured via metallic additive manufacturing technology. By varying the design parameters such as cell size, strut length, and strut diameter of the unit cells in lattice structures, a gradient property is obtained to achieve different levels of functionalities and optimize strength-to-weight ratio characteristics. Gradient lattice structures offer variable densification and porosities; and can combine more than one type of unit cells with different topologies which results in different performances in mechanical behavior layer-by-layer compared to non-gradient lattice structures. Additive manufacturing techniques are capable of manufacturing complex lightweight parts such as uniform and gradient lattice structures and hence offer design freedom for engineers. Despite these advantages, additive manufacturing has its own unique drawbacks in manufacturing lattice structures. The rules and strategies in overcoming the constraints are discussed and recommendations for future work were proposed.

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“…Therefore, DLS is a potential technique to manufacture porous materials. Erdal et al (2010) showed clearly that the porosity of the structure obtained by DLS could be changed by varying laser energy input and liquid phase content. However, as Agarwala et al (1995) pointed out, high-porosity sintered part could not be obtained by this way because of low strength of such samples.…”

Section: Introductionmentioning

confidence: 97%

Fabrication of high porosity Cu-based structure using direct laser sintering

Fang

Chen

2016

Rapid Prototyping Journal

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Purpose – The purpose of this paper is to report the investigation on obtaining a high-porosity Cu-based structure which was sintered successfully using direct laser sintering and to reveal the mechanisms of obtaining high porosity and acceptable strength simultaneously as well as the effect of NaCl content on characteristics of the sintered samples. Design/methodology/approach – Experimental study has been performed. The powder mixture utilized in this experiment includes metal powder (Cu and Cu3P mixture) and porogen [sodium chloride (NaCl)]. Scanning electron microscope, energy-dispersive X-ray analysis and the Archimedes density measurement were used to detect the characteristics of the sintered sample and to reveal the mechanism of forming high porosity and strength structure. Findings – More than 57 per cent porosity can be achieved while the structural strength is acceptable, and the infiltrated experiment verifies the pores in the structure are inter-connected. During laser sintering, NaCl powder melts and brings a larger amount of liquid phase, inducing large rearrange force and fast rearrangement of Cu particles. Therefore, after NaCl is removed, the dense and strong longer-bar shape tracks with larger amount of pores in the microstructure can be obtained. The size of pores as well as the porosity of the sintered sample increase with the NaCl content in the powder mixture. Originality/value – The mechanism of obtaining high porosity and acceptable strength simultaneously was revealed. The effect of NaCl content on characteristics of the sintered samples was also disclosed.

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Manufacturing of Functionally Graded Porous Products by Selective Laser Sintering

Cited by 20 publications

References 3 publications

A Comprehensive Overview on the Latest Progress in the Additive Manufacturing of Metal Matrix Composites: Potential, Challenges, and Feasible Solutions

A Comprehensive Overview on the Latest Progress in the Additive Manufacturing of Metal Matrix Composites: Potential, Challenges, and Feasible Solutions

A review on integration of lightweight gradient lattice structures in additive manufacturing parts

Fabrication of high porosity Cu-based structure using direct laser sintering

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