Optimizing Laser Powder Bed Fusion Parameters for IN-738LC by Response Surface Method

Vilanova, M.; Escribano-García, Rubén; Guraya, Teresa; Sebastián, María San

doi:10.3390/ma13214879

Cited by 23 publications

(10 citation statements)

References 33 publications

Supporting

Mentioning

Contrasting

Order By: Relevance

“…The use of trial-and-error is one of the options available to optimize the associated parameters, but this approach is not suitable for current industries using complex manufacturing processes, as it is time-consuming and costly [ 3 ]. Therefore, applying optimisation methods such as the Response Surface Methodology (RSM), Genetic Algorithm (GA), Particle Swarm Optimisation (PSO) and Taguchi is a good option to optimise the setting of processing parameters to mould parts with better quality [ 4 , 5 , 6 , 7 , 8 , 9 , 10 , 11 , 12 ].…”

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Optimisation of Shrinkage and Strength on Thick Plate Part Using Recycled LDPE Materials

et al. 2021

View full text Add to dashboard Cite

Achieving good quality of products from plastic injection moulding processes is very challenging, since the process comprises many affecting parameters. Common defects such as warpage are hard to avoid, and the defective parts will eventually go to waste, leading to unnecessary costs to the manufacturer. The use of recycled material from postindustrial waste has been studied by a few researchers. However, the application of an optimisation method by which to optimise processing parameters to mould parts using recycled materials remains lacking. In this study, Response Surface Methodology (RSM) and Particle Swarm Optimisation (PSO) methods were conducted on thick plate parts moulded using virgin and recycled low-density polyethylene (LDPE) materials (100:0, 70:30, 60:40 and 50:50; virgin to recycle material ratios) to find the optimal input parameters for each of the material ratios. Shrinkage in the x and y directions increased in correlation with the recycled ratio, compared to virgin material. Meanwhile, the tensile strength of the thick plate part continued to decrease when the recycled ratio increased. R30 (70:30) had the optimum shrinkage in the x direction with respect to R0 (100:0) material where the shrinkage increased by 24.49% (RSM) and 33.20% (PSO). On the other hand, the shrinkage in the y direction for R30 material increased by 4.48% (RSM) and decreased by 2.67% (PSO), while the tensile strength of R30 (70:30) material decreased by 0.51% (RSM) and 2.68% (PSO) as compared to R0 (100:0) material. Validation tests indicated that the optimal setting of processing parameter suggested by PSO and RSM for R0 (100:0), R30 (70:30), R40 (60:40) and R50 (50:50) was less than 10%.

show abstract

Section: Introductionmentioning

confidence: 99%

“…RSM is among the optimisation methods that have been used by many researchers [ 6 , 7 , 8 , 9 , 10 ]. Sudsawat and Sriseubsai [ 10 ] conducted research using the RSM optimisation approach to create optimal process settings to minimise warpage and volume shrinkage. General Purpose Polystyrene (GPPS) was used as the material.…”

Section: Introductionmentioning

confidence: 99%

Optimisation of Shrinkage and Strength on Thick Plate Part Using Recycled LDPE Materials

et al. 2021

View full text Add to dashboard Cite

show abstract

“…Actually, 90° scan strategy, which is defined as the rotation of layers, was selected because it was observed in the previous work that crack formation was favored in this scan strategy. The obtained energy density value is inside the optimal range defined by Vilanova et al [ 28 ].…”

Section: Methodsmentioning

confidence: 57%

“…Samples with the dimensions described in the image of Table 3 were manufactured in order to ease the extraction from the platform. The samples were manufactured with a Renishaw RenAM 500Q machine, which employs 4 Yb-fiber lasers in pulsed or continuous mode with a beam diameter of 85 µm and a maximum laser power of 500 W. Based on the results obtained in a preliminary research work [ 28 ], samples were processed using laser continuous mode and the process parameters described in Table 3 . Actually, 90° scan strategy, which is defined as the rotation of layers, was selected because it was observed in the previous work that crack formation was favored in this scan strategy.…”

Section: Methodsmentioning

confidence: 99%

Influence of Minor Alloying Element Additions on the Crack Susceptibility of a Nickel Based Superalloy Manufactured by LPBF

et al. 2021

Self Cite

View full text Add to dashboard Cite

Inconel 738LC (IN738LC) is a nickel-based superalloy specially used in the hot section components of turbine engines. One of its main drawbacks relies on the cracking susceptibility when it is manufactured by laser powder bed fusion (LPBF). This paper analyzes the influence of minor alloying element concentration on cracking tendency of IN738LC superalloy manufactured by LPBF. For that objective, samples were manufactured using two powders, which presented different minor alloying elements concentration (Si, Zr and B). It was shown that the samples crack tendency was very different depending on the powder used for their manufacturing. In fact, the measured crack density value was 2.73 mm/mm2 for the samples manufactured with the powder with higher minor alloying elements concentration, while 0.25 mm/mm2 for the others. Additionally, a special emphasis has been put on elemental composition characterization in cracked grain boundaries in order to quantify possible Si or Zr enrichment. It has been also studied the differences of solidification ranges and grain structures between both samples as a consequence of different minor alloying elements concentration in order to analyze their effect on crack susceptibility. In this sense, Scheil-Gulliver simulation results have shown that samples with higher Si and Zr contents presented higher solidification range temperature. This fact, as well as an increase of the presence of high angle grain boundaries (HAGB), leaded to an increment in the crack formation during solidification. Therefore, in this research work, an understanding of the factors affecting crack phenomenon in the LPBF manufactured IN738LC was accomplished.

show abstract

“…However, Wang et al showed that an excessive VED leads to a higher surface roughness and to an increase of the specimen porosity [24]. In another work it was found that the laser power, the feed rate and the combination of both have a significant influence on porosity and cracking [28]. Another method of reducing the roughness of the individual layers is based on remelting the surfaces of the previously built-up layer before a new layer of powder is applied [29,30].…”

Section: Introductionmentioning

confidence: 99%

Individual process development of single and multi-material laser melting in novel modular laser powder bed fusion system

et al. 2022

View full text Add to dashboard Cite

Additive manufacturing and especially the laser-based powder bed fusion (LPBF) with full melting of the powder offers tremendous potential and versatility for manufacturing high quality, complex, precision metal parts. However, for novel powder compositions the LPBF process development is very time consuming and cost intensive due to the layer wise melting and the powder prices. This research work investigates the manufacturing of single and layered multi-material structures in a novel modular lab-scaled LPBF machining system through individual process and material development. The developed system allows the use of different laser sources, optical arrangements, individual sensor and actuator integration. In addition, the modular LPBF system enables the manufacturing of specimens with a minimum amount of powder, individual mixed powder compositions or layered multi-material parts. In an application example, a multi-material specimen made out of stainless steel 316L and Bronze 90/10 was manufactured in alternating layers. For this approach, a parameter study was performed for each material to investigate the influence of the volumetric energy density (VED) on the specimen density, surface flatness and reduced mixing zone formation. Afterwards, optimized parameters were used to demonstrate the feasibility of the system to produce a multi-material layered 316L-Bronze part.

show abstract

Optimizing Laser Powder Bed Fusion Parameters for IN-738LC by Response Surface Method

Cited by 23 publications

References 33 publications

Optimisation of Shrinkage and Strength on Thick Plate Part Using Recycled LDPE Materials

Optimisation of Shrinkage and Strength on Thick Plate Part Using Recycled LDPE Materials

Influence of Minor Alloying Element Additions on the Crack Susceptibility of a Nickel Based Superalloy Manufactured by LPBF

Individual process development of single and multi-material laser melting in novel modular laser powder bed fusion system

Contact Info

Product

Resources

About