Recoater-Induced Distortions and Build Failures in Selective Laser Melting of Thin-Walled Ti6Al4V Parts

Lu, Xufei; Chiumenti, Michele; Cervera, Miguel; Slimani, Mehdi; Gonzalez, Iban

doi:10.3390/jmmp7020064

Cited by 7 publications

(3 citation statements)

References 55 publications

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“…These studies delve into SLM's capabilities in producing intricate and lightweight components for various industries. Their findings contribute to advancing AM techniques and applications [48][49][50][51]. Studies have shown that the quality and reliability of thin-walled products produced using SLM are significantly influenced by various process parameters, including powder layer thickness, hatching distance, and laser power [50,52].…”

Section: Selective Laser Melting For Thin-walled Partsmentioning

confidence: 94%

Critical Review of Comparative Study of Selective Laser Melting and Investment Casting for Thin-Walled Parts

Dejene,

Lemu,

Gutema

2023

Materials

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Thin-walled structures are a significant and growing portion of engineering construction, with a wide range of applications, including storage vessels, industrial buildings, warehouses, aircraft, automobiles, bridges, ships, and oil rigs. Thin-walled components with minimum thickness without compromising strength and other quality characteristics are the desire of modern industry. Reducing wall thickness not only aids in lowering the cost of production. It also improves the effectiveness of engineering systems, resulting in lower fuel consumption and lower emissions of hazardous gases to the environment. Nowadays, even though thin-walled parts are demanded, the constraints of the production process, quality, and reliability are the concerns of current research and development. The ability to produce parts with intricate geometries and tight dimensional tolerances are important criteria for advanced manufacturing processes. In the early days of society, investment casting was used to produce jewelry, weapons, and statues. In modern industry, investment casting is still used to produce thin-walled and intricate parts such as turbine blades. The current advancements in SLM, which has the capacity to produce thin-walled and intricate parts, have recently attracted attention due to several benefits, such as the supreme degree of design freedom and the viability of tool-free production directly from CAD data. However, the current technological applications of SLM and investment casting are crucial for producing parts at the desired quality and reliability. This review article focuses on comparative studies of SLM and investment casting at the current technology level. The basis of comparison via systematic approach is mechanical characterization; quality in terms of porosity, microstructure, surface roughness and dimensional accuracy; and residual stress. Therefore, the latest open scientific sources published are considered to obtain sufficient literature coverage. Better tensile strength and fine microstructure are found in SLM, while better surface quality, fatigue load resistance, ductility, and residual stress are found in investment casting. The research gap for further investigation is indicated.

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Section: Selective Laser Melting For Thin-walled Partsmentioning

confidence: 94%

Critical Review of Comparative Study of Selective Laser Melting and Investment Casting for Thin-Walled Parts

Dejene,

Lemu,

Gutema

2023

Materials

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“…Adapted from ref. [29]. The heat exchange was defined also for the specimen using the same parameters previously discussed for the heat exchange between the plate and the environment.…”

Section: Fem Model For L-pbfmentioning

confidence: 99%

Finite Element Method in L-PBF of Ti-6Al-4V: Influence of Laser Power and Scan Speed on Residual Stress and Part Distortion

Palmeri,

Pollara,

Licari

et al. 2023

Metals

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Laser powder bed fusion (L-PBF) is widely used in automotive, aerospace, and biomedical applications thanks to its ability to produce complex geometries. In spite of its advantages, parts produced with this technology can show distortion due to the residual stresses developed during the printing process. For this reason, numerical simulations can be used to predict thermal gradients and residual stresses that can result in part distortion. Thus, instead of performing experimental tests and using a trial and error approach, it is possible to use numerical simulation to save time and material. In this work, the effect of laser power and scan speed on residual stress and part distortion was analysed using a commercial finite element analysis (FEA) software DEFORM-3D™ with a layer-by-layer approach. Moreover, the accuracy of the numerical model with respect to process parameters and the utilised mesh was also studied. The results obtained from the numerical simulation were compared to the actual distortions to evaluate the accuracy of the FEM model. The predicted distortions using FEM analysis well fit the trend of the measured ones. The accuracy of the numerical model increases by considering a finer mesh.

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“…Cheng et al [41] compared the experimental results with the Simufact simulation tool, where they used a multiscale approach method to analyse the part distortion. Some authors investigated the prediction of distortion, using a method incorporating a mathematical heat source model for thermo-mechanical finite element analysis -FEA [42]. This was a method where the powder is considered as the input material.…”

Section: Introductionmentioning

confidence: 99%

Simulation Tool for Material Behaviour Prediction in Additive Manufacturing

Kaščák¹,

Varga²,

Bidulská³

et al. 2023

Acta Metall Slovaca

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Simulation tools play an important role not only in terms of understanding the processes taking place in the production, and the possibility to prevent failures, but ultimately, and most importantly, to optimize the production process. Thus, simulation tools should be able to work with many input parameters. The processes in which many parameters influence the final quality of the part, and its properties is metal additive manufacturing (AM). The volume of support material used in the metal AM process is also of importance, as its reduction plays an important role in terms of cost-effectiveness, which can be increased by minimizing support structures. The paper deals with the numerical simulation of the metal AM process. The simulation analyses with the same input parameters were performed, comparing each other the support material distribution, volume fraction or shape deviation with respect to the conventional support generation method and the function allowing the support generation by means of the optimization mode. Less variation in the shape of the part, variation in its volume fraction, variation in the density of the generated support structures as well as variation in the spacing of the generated support structure was achieved by using the support generation optimization mode.

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Recoater-Induced Distortions and Build Failures in Selective Laser Melting of Thin-Walled Ti6Al4V Parts

Cited by 7 publications

References 55 publications

Critical Review of Comparative Study of Selective Laser Melting and Investment Casting for Thin-Walled Parts

Critical Review of Comparative Study of Selective Laser Melting and Investment Casting for Thin-Walled Parts

Finite Element Method in L-PBF of Ti-6Al-4V: Influence of Laser Power and Scan Speed on Residual Stress and Part Distortion

Simulation Tool for Material Behaviour Prediction in Additive Manufacturing

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