On the limitations of Volumetric Energy Density as a design parameter for Selective Laser Melting

Bertoli, Umberto Scipioni; Wolfer, Alexander J.; Matthews, Manyalibo J.; Delplanque, Jean‐Pierre; Schoenung, Julie M.

doi:10.1016/j.matdes.2016.10.037

Cited by 574 publications

(151 citation statements)

References 28 publications

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“…10). Considering the same approach than (Hann et al, 2011), already used by Scipioni Bertoli et al (2017). for SLM, we also tried to correlate normalized bead penetrations (e/D) for both materials with a normalized enthalpy value ΔH/h s incorporating the thermo-physical properties of irradiated materials (diffusivity α).…”

Section: Analysis Of Melt-pool Shapes and Affected Depthsmentioning

confidence: 99%

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Experimental analysis of spatter generation and melt-pool behavior during the powder bed laser beam melting process

Gunenthiram

Peyre

Schneider

et al. 2018

Journal of Materials Processing Technology

276

120

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is an open access repository that collects the work of Arts et Métiers ParisTech researchers and makes it freely available over the web where possible. A B S T R A C TThe experimental analysis of spatter formation was carried out on an instrumented SLM set-up allowing the quantification of spatter ejections and possible correlation with melt-pool behavior. Considering nearly similar SLM conditions than those carried out on SLM machines, an increase of large spatters (> 80 μm) with volume energy density (VED) was clearly demonstrated on a 316L stainless steel, which was attributed to the recoil pressure applied on the melt-pool by the metal vaporization and the resulting high velocity vapor plume. In a second step, much lower spattering was shown on Al-12Si powder beds than on 316L ones. Fast camera analysis of powder beds indicated that droplet formation was mostly initiated in the powder-bed near the melt-pool interface. On Al-12 Si alloys, such droplets were directly incorporated in the MP without being ejected upwards as spatters like on 316L. Last, it was shown that a strong reduction of spattering was possible even on 316L, with the use of low VED combined with larger spots (≈0.5 mm), allowing to melt sufficiently deep layers in conduction regime and ensure adequate dilution between layers.

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Section: Analysis Of Melt-pool Shapes and Affected Depthsmentioning

confidence: 99%

“…However Scipioni Bertoli et al (2017) mentioned that such a parameter is not fully sufficient to predict the stable SLM regimes, due to the complex physics involved either at low VED or at high VED values.…”

Section: Introductionmentioning

confidence: 99%

Experimental analysis of spatter generation and melt-pool behavior during the powder bed laser beam melting process

Gunenthiram

Peyre

Schneider

et al. 2018

Journal of Materials Processing Technology

276

120

View full text Add to dashboard Cite

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“…Unfortunately, it appears that this convenient approach via the characterization with a single number is not able to sufficiently express the entire complexity of powder-bed based AM processes, like SLM [10][11][12]. Thus, at this stage, a proper description of the manufacturing process still requires the listing of the individual irradiation parameters.…”

Section: Introductionmentioning

confidence: 99%

On the Anisotropic Mechanical Properties of Selective Laser Melted Stainless Steel

Hitzler

Hirsch

Heine

et al. 2017

Preprint

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Abstract:The thorough description of the peculiarities of additively manufactured structures represents a current challenge for aspiring freeform fabrication methods, such as the selective laser melting (SLM). All of which have an immense advantage in the fast fabrication (no special tooling or moulds required), the geometrical flexibility in the design of components, and their efficiency when only low quantities are required. However, designs demand the precise knowledge of the material properties, which in case of additively manufactured structures are anisotropic and, under certain circumstances, in addition of an inhomogeneous nature. Furthermore, these characteristics are highly dependent on the fabrication settings. Within this study, the anisotropic tensile properties of selective laser melted stainless steel (1.4404, 316L) are investigated: The Young's modulus ranged from 148 GPa to 227 GPa, the ultimate tensile strength from 512 MPa to 699 MPa and the breaking elongation ranged, respectively, from 12% to 43%. The results were compared to related studies, in order to classify the influence of the fabrication settings. Furthermore, the influence of the chosen raw material was addressed by comparing deviations on the directional dependencies reasoned by differing microstructural developments during manufacture. Stainless steel was found to possess its maximum strength at a 45° layer versus loading offset, which is precisely where AlSi10Mg was previously reported to be at its weakest.

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“…Other less common in situ process optimization methods such as on-line process monitoring and in-line quality control have also been investigated, but are challenging to implement reliably into existing machine technologies [12–14]. The use of volumetric heat-source energy density to optimize printing parameters has also been investigated, but has been shown to lack necessary information about the thermal phenomena that occurs during the process, and can be too generalized to apply to many different material systems [15]. In general, these techniques require significant setup time and materials which quickly increase production costs and are largely non-transferable among material systems and machines.…”

Section: Introductionmentioning

confidence: 99%

Invited review article: Metal-additive manufacturing—Modeling strategies for application-optimized designs

Bandyopadhyay

Traxel

2018

Additive Manufacturing

128

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Next generation, additively-manufactured metallic parts will be designed with application-optimized geometry, composition, and functionality. Manufacturers and researchers have investigated various techniques for increasing the reliability of the metal-AM process to create these components, however, understanding and manipulating the complex phenomena that occurs within the printed component during processing remains a formidable challenge—limiting the use of these unique design capabilities. Among various approaches, thermomechanical modeling has emerged as a technique for increasing the reliability of metal-AM processes, however, most literature is specialized and challenging to interpret for users unfamiliar with numerical modeling techniques. This review article highlights fundamental modeling strategies, considerations, and results, as well as validation techniques using experimental data. A discussion of emerging research areas where simulation will enhance the metal-AM optimization process is presented, as well as a potential modeling workflow for process optimization. This review is envisioned to provide an essential framework on modeling techniques to supplement the experimental optimization process.

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On the limitations of Volumetric Energy Density as a design parameter for Selective Laser Melting

Cited by 574 publications

References 28 publications

Experimental analysis of spatter generation and melt-pool behavior during the powder bed laser beam melting process

Experimental analysis of spatter generation and melt-pool behavior during the powder bed laser beam melting process

On the Anisotropic Mechanical Properties of Selective Laser Melted Stainless Steel

Invited review article: Metal-additive manufacturing—Modeling strategies for application-optimized designs

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