Quantification and Analysis of Residual Stresses in Braking Pedal Produced via Laser–Powder Bed Fusion Additive Manufacturing Technology

Fojtík, František; Potrok, Roman; Hajnyš, Jiří; Ma, Quoc-Phu; Kudrna, Lukáš; Měsíček, Jakub

doi:10.3390/ma16175766

Cited by 2 publications

(1 citation statement)

References 28 publications

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“…To address this, the deviation can be scaled using a calibration sample, which also serves for Simufact Additive software simulations. [ 31 ] The combination of standard LS design in EN2243‐1 and Simufact Additive software simulations can scale both detached force and part deviation with a special design called shear deviation (SD). This design closely mimics the behavior of support structures in L‐PBF.…”

Section: Methodsmentioning

confidence: 99%

Advanced Support Structures in Metal Additive Manufacturing: A Comparative Analysis of Porous Media for Enhanced Part Quality and Removal Efficiency

Erol,

Gülletutan,

Günaydın

et al. 2024

Adv Eng Mater

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In laser powder bed fusion additive manufacturing support, structures are crucial for constructing overhang features and maintaining dimensional accuracy. However, traditional support structures exhibit inherent drawbacks, including compromised surface quality, prolonged post‐processing times, and other challenging requirements. This study investigates innovative approaches to address these issues by analyzing two types of specimens—cuboid and lap shear. The cuboid samples explore the manipulation of process parameters to adjust energy densities, transitioning from powder to porous support structures, with porosity measurement assessment. Subsequently, a shear test specimen objectively evaluates porous support parameters alongside traditional block‐type support, analyzing their impact on removal force, distortion, and surface quality. Results reveal that optimized porous support structures surpass traditional counterparts, showcasing superior surface quality, reduced removal forces, and minimized part distortion. Specifically, the shear test demonstrates a 94.25% reduction in removal forces and a 33.67% decrease in upper part distortion. Moreover, the maximum surface roughness (Rz) improves by 22.8% with the implementation of porous supports. By introducing a methodology for comparative analyses of measurable performance indicators, this research enhances understanding of support structure dynamics in additive manufacturing, facilitating advancements in efficiency and quality within the field.This article is protected by copyright. All rights reserved.

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Section: Methodsmentioning

confidence: 99%

Advanced Support Structures in Metal Additive Manufacturing: A Comparative Analysis of Porous Media for Enhanced Part Quality and Removal Efficiency

Erol,

Gülletutan,

Günaydın

et al. 2024

Adv Eng Mater

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Laser sintering of metal powders: failure analysis and implementation of solutions for aluminium and stainless steel parts

Szabó,

Kun

2024

Mater. Res. Express

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In this research, the failures and possible solutions of direct metal laser sintering (DMLS) have been investigated, with the aim of presenting an overview of the current state of science and possible technical solutions to the various challenges and potential solutions. DMLS technology allows to produce high density parts and has proven to be suitable for the cost-effective production of both mass-produced and individual parts in the automotive, aerospace, medical and hydrogen technology industries. This study reveals the fundamental principles, potential benefits, and limitations of metal 3D printing. The defects are categorized into those related to raw materials and those caused by the manufacturing process. The properties of the parts fabricated by this method are mainly depending on the quality of the raw material and the intensity of the laser beam. Clusters of raw materials have a negative impact on the whole manufacturing process, requiring their investigation and avoidance. Another critical defect identified is the significant internal stress generated during the manufacturing process. Various methods are developed to quantify and mitigate these internal stresses. This study provides a detailed analysis of these defects and their impacts, along with a review of literature-based solutions. Among the evaluated and implemented solutions, emphasis is placed on the effects of preheating the build plate and post-process heat treatment. Future objectives and research directions are proposed, presenting and assessing alternative solutions such as Vibratory Stress Relief (VSR) and Thermo-Vibratory Stress Relief (TVSR), which combine heat treatment with vibration. In the scope of the research, the process by which the most common failures occur, and their potential outcomes was reviewed. Special attention was given to deformation caused by internal stress and the possibilities for its mitigation. The feasibility of applying a new approach was investigated, and future research objectives were outlined. SEM imaging was employed to conduct and analyse the grain size of stainless-steel raw material, and agglomerates were observed in the post-print recycled powder.

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Quantification and Analysis of Residual Stresses in Braking Pedal Produced via Laser–Powder Bed Fusion Additive Manufacturing Technology

Cited by 2 publications

References 28 publications

Advanced Support Structures in Metal Additive Manufacturing: A Comparative Analysis of Porous Media for Enhanced Part Quality and Removal Efficiency

Advanced Support Structures in Metal Additive Manufacturing: A Comparative Analysis of Porous Media for Enhanced Part Quality and Removal Efficiency

Laser sintering of metal powders: failure analysis and implementation of solutions for aluminium and stainless steel parts

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