Powder recycling effects on porosity development and mechanical properties of Hastelloy X alloy during laser powder bed fusion process

He, Xing; Kong, Decheng; Zhou, Yiqi; Wang, Li; Ni, Xiaoqing; Zhang, Liang; Wu, Wenheng; Li, Ruixue; Li, Yong; Dong, Chaofang

doi:10.1016/j.addma.2022.102840

Cited by 23 publications

(16 citation statements)

References 62 publications

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“…Similar to the PSD and sphericity, the flowability of reused powders measured based on the HR [195], Hall/Carney funnel [191], RPA [195], FT4 [196], or Granudrum [194] does not reach a unified conclusion, which depends on the specific alloy systems. • 316L [191,197] • Hastelloy [198],…”

Section: Powder Degradation During Powder Reusementioning

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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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: Powder Degradation During Powder Reusementioning

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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“…Due to the wettability of Hastelloy X powder, it produces more spatters, which affects the re-cycling of the powder. He et al [98] found that after 6 cycles of Hastelloy, the average particle size increased by 22% and the oxygen content increased by 48%, and the part porosity increased, resulting in a reduced part quality. The following Table 7 summarizes the number of re-cycle times available for different powders.…”

Section: Effect Of Spatter On Powder Recyclingmentioning

confidence: 99%

A Review of Spatter in Laser Powder Bed Fusion Additive Manufacturing: In Situ Detection, Generation, Effects, and Countermeasures

Yin

et al. 2022

Micromachines

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Spatter is an inherent, unpreventable, and undesired phenomenon in laser powder bed fusion (L-PBF) additive manufacturing. Spatter behavior has an intrinsic correlation with the forming quality in L-PBF because it leads to metallurgical defects and the degradation of mechanical properties. This impact becomes more severe in the fabrication of large-sized parts during the multi-laser L-PBF process. Therefore, investigations of spatter generation and countermeasures have become more urgent. Although much research has provided insights into the melt pool, microstructure, and mechanical property, reviews of spatter in L-PBF are still limited. This work reviews the literature on the in situ detection, generation, effects, and countermeasures of spatter in L-PBF. It is expected to pave the way towards a novel generation of highly efficient and intelligent L-PBF systems.

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“…Luo et al (2022) established the process structure property relationship in SLM of Ti 6 Al 4 V where higher energy density leads to improved mechanical properties. He et al (2022) investigated the effect of powder reusability on porosity formation and mechanical properties in SLM where the results produced a 20.8% reduction in the plasticity and an enhanced porosity of the recycled powder compared to virgin one. Stef et al (2018) revealed that the crack formation and mechanical performance vary directly by the presence and distribution of pores in SLM of Ti 6 Al 4 V. El-Sayed et al (2020) performed the design optimization in SLMed Ti to get controlled porosity for trabecular bone replacement surgeries.…”

Section: Introductionmentioning

confidence: 99%

Manufacturability study in laser powder bed fusion of biomedical Ti alloys for orthopedic implants: an investigation of mechanical properties, process-induced porosity and surface roughness

Rehman

Wang

Ishfaq

et al. 2023

RPJ

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Purpose Since the biomedical implants with an improved compressive strength, near bone elastic modulus, controlled porosity, and sufficient surface roughness, can assist in long term implantation. Therefore, the fine process tuning plays its crucial role to develop optimal settings to achieve these desired properties. This paper aims to find applications for fine process tuning in laser powder bed fusion of biomedical Ti alloys for load-bearing implants. Design/methodology/approach In this work, the parametric porosity simulations were initially performed to simulate the process-induced porosity for selective laser-melted Ti6Al4V as per full factorial design. Continually, the experiments were performed to validate the simulation results and perform multiresponse optimization to fine-tune the processing parameters. Three levels of each control variable, namely, laser power – Pl (180, 190, 200) W, scanning speed – Vs (1500, 1600, 1700) mm/s and scan orientation – ϴ{1(0,0), 2(0,67°), 3(0,90°)} were used to investigate the processing performance. The measured properties from this study include compressive yield strength, elastic modulus, process-induced porosity and surface roughness. Finally, confirmatory experiments and comparisons with the already published works were also performed to validate the research results. Findings The results of porosity parametric simulation and experiments in selective laser melting of Ti6Al4V were found close to each other with overall porosity (less than 10%). The fine process tuning was resulted in optimal settings [Pl (200 W), Vs (1500 mm/s), ϴ (0,90°)], [Pl (200 W), Vs (1500 mm/s), ϴ (0,67°)], [Pl (200 W), Vs (1500 mm/s), ϴ (0,0)] and [Pl (200 W), Vs (1500 mm/s), ϴ (0,0)] with higher compressive strength (672.78 MPa), near cortical bone elastic modulus (12.932 GPa), process-induced porosity (0.751%) and minimum surface roughness (2.72 µm). The morphology of the selective laser melted (SLMed) surface indicated that the lack of fusion pores was prominent because of low laser energy density among the laser and powder bed. Confirmatory experimentation revealed that an overall percent improvement of around 15% was found between predicted and the experimental values. Originality/value Since no significant works are available on the collaborative optimization and fine process tuning in laser powder bed fusion of biomedical Ti alloys for different load bearing implants. Therefore, this work involves the comprehensive investigation and multi-objective optimization to determine optimal parametric settings for better mechanical and physical properties. Another novel aspect is the parametric porosity simulation using Ansys Additive to assist in process parameters and their levels selection. As a result, selective laser melted Ti alloys at optimal settings may help in examining the possibility for manufacturing metallic implants for load-bearing applications.

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Powder recycling effects on porosity development and mechanical properties of Hastelloy X alloy during laser powder bed fusion process

Cited by 23 publications

References 62 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

A Review of Spatter in Laser Powder Bed Fusion Additive Manufacturing: In Situ Detection, Generation, Effects, and Countermeasures

Manufacturability study in laser powder bed fusion of biomedical Ti alloys for orthopedic implants: an investigation of mechanical properties, process-induced porosity and surface roughness

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