Powder Reuse Cycles in Electron Beam Powder Bed Fusion—Variation of Powder Characteristics

Shanbhag, Gitanjali; Vlasea, Mihaela

doi:10.3390/ma14164602

Cited by 30 publications

(11 citation statements)

References 36 publications

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“…The hypothesis based on the literature data about other powder materials [ 32 , 33 , 34 ] was that AlSi7Mg0.6 powder would degrade with each cycle: its surface would be oxidised and PSD would increase toward bigger particles [ 35 ]. Therefore, it was expected that the laser absorption would change due to the surface oxidation and PSD, impacting the process conditions and the final sample properties.…”

Section: Discussionmentioning

confidence: 99%

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

et al. 2022

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Additive manufacturing (AM) is dynamically developing and finding applications in different industries. The quality of input material is a part of the process and of the final product quality. That is why understanding the influence of powder reuse on the properties of bulk specimens is crucial for ensuring the repeatable AM process chain. The presented study investigated the possibility of continuous reuse of AlSi7Mg0.6 powder in the laser powder bed fusion process (LPBF). To date, there is no study of AlSi7Mg0.6 powder reuse in the LPBF process to be found in the literature. This study aims to respond to this gap. The five batches of AlSi7Mg0.6 powder and five bulk LPBF samples series were characterised using different techniques. The following characteristics of powders were analysed: the powder size distribution (PSD), the morphology (scanning electron microscopy—SEM), the flowability (rotating drum analysis), and laser light absorption (spectrophotometry). Bulk samples were characterised for microstructure (SEM), chemical composition (X-ray fluorescence spectrometry—XRF), porosity (computed tomography—CT) and mechanical properties (tensile, hardness). The powder was reused in subsequent processes without adding (recycling/rejuvenation) virgin powder (collective ageing powder reuse strategy). All tested powders (powders P0–P4) and bulk samples (series S0–S3) show repeatable properties, with changes observed within error limits. Samples manufactured within the fifth reuse cycle (series S4) showed some mean value changes of measured characteristics indicating initial degradation. However, these changes also mostly fit within error limits. Therefore, the collective ageing powder reuse strategy is considered to give repeatable LPBF process results and is recommended for the AlSi7Mg0.6 alloy within at least five consecutive LPBF processes.

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Section: Discussionmentioning

confidence: 99%

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

et al. 2022

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“…The method is open to different possible extensions and improvements, in terms of both image processing algorithms and image acquisition equipment, including the use of ad hoc illumination sources or a selective use of the radiation spectrum to enhance the characterization of the powder bed surface. As a future development, powder bed monitoring in EBM can be further extended by exploiting different sensing methods to detect and characterize other phenomena of interest, such as surface powder oxidation [33,34], which is currently not feasible with the proposed approach.…”

Section: Discussionmentioning

confidence: 99%

In Situ Monitoring of Powder Bed Fusion Homogeneity in Electron Beam Melting

Grasso

2021

Materials

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Increasing attention has been devoted in recent years to in situ sensing and monitoring of the electron beam melting process, ranging from seminal methods based on infrared imaging to novel methods based on backscattered electron detection. However, the range of available in situ monitoring capabilities and solutions is still quite limited compared to the wide number of studies and industrial toolkits in laser-based additive manufacturing processes. Some methods that are already industrially available in laser powder bed fusion systems, such as in situ detection of recoating errors, have not yet been investigated and tested in electron beam melting. Motivated by the attempt to fill this gap, we present a novel in situ monitoring methodology that can be easily implemented in industrial electron beam melting machines. The method is aimed at identifying local inhomogeneity and irregularities in the powder bed by means of layerwise image acquisition and processing, with no external illumination source apart from the light emitted by the hot material underneath the currently recoated layer. The results show that the proposed approach is suitable to detect powder bed anomalies, while also highlighting the link between the severity of in situ detected errors and the severity of resulting defects in the additively manufactured part.

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“…This is due to the penetration of digital technologies into everyday life and the development of alternative energy and electrical vehicles [ 115 ]. Modern industrial development cannot proceed without efficient re-use and recycling procedures [ 116 , 117 , 118 , 119 ]. …”

Section: Ingredients Of An Industry 40 Healthcare Systemmentioning

confidence: 99%

“…Modern industrial development cannot proceed without efficient re-use and recycling procedures [ 116 , 117 , 118 , 119 ].…”

Section: Ingredients Of An Industry 40 Healthcare Systemmentioning

confidence: 99%

Industry 4.0 and Digitalisation in Healthcare

et al. 2022

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Industry 4.0 in healthcare involves use of a wide range of modern technologies including digitisation, artificial intelligence, user response data (ergonomics), human psychology, the Internet of Things, machine learning, big data mining, and augmented reality to name a few. The healthcare industry is undergoing a paradigm shift thanks to Industry 4.0, which provides better user comfort through proactive intervention in early detection and treatment of various diseases. The sector is now ready to make its next move towards Industry 5.0, but certain aspects that motivated this review paper need further consideration. As a fruitful outcome of this review, we surveyed modern trends in this arena of research and summarised the intricacies of new features to guide and prepare the sector for an Industry 5.0-ready healthcare system.

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Powder Reuse Cycles in Electron Beam Powder Bed Fusion—Variation of Powder Characteristics

Cited by 30 publications

References 36 publications

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

Influence of the AlSi7Mg0.6 Aluminium Alloy Powder Reuse on the Quality and Mechanical Properties of LPBF Samples

In Situ Monitoring of Powder Bed Fusion Homogeneity in Electron Beam Melting

Industry 4.0 and Digitalisation in Healthcare

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