Research on Cladding Process of Metal Powder during Laser Additive Manufacturing

Abstract

The process of laser additive manufacturing consists of depositing successive layers of molten metal powder to create a near-net shape. A high-power laser is used to melt incoming metal powder, which forms a molten pool on the surface. As the latter moves beneath the laser, this newly created molten pool solidifies. By properly controlling the trajectory of deposition tracks, one can create a diverse range of shapes with varying complexities. In nature, the laser additive manufacturing technology is a continuous multilayer laser cladding process under the control of computer. The microstructure morphology of cladding layer is essential for the performance of as-deposited metal parts, so the cladding process was studied through related experiment. Based on the solidification theory, the microstructure morphology and the evolution rule were comprehensively analyzed. The results indicate that the temperature gradient and the solidification rate are the primary factor determining the microstructure morphology of cladding layer.

Additive Manufacturing Technologies and Applications

“…In addition, there has been significant efforts targeting quality control for low-cost FFF 3D printers both informally [77][78][79] and formally [80][81][82] to enable real-time control, which when widespread will only enhance the conclusions in this study.…”

“…While this is the most common technique, besides post-processing, to optimize parts, it depends mostly on the experience and intuition of the user and is usually not applicable to general problems using SLM/DMLS. While many case studies and part-and machine-specific solutions have been published, the best documented and most widely-cited solutions that analyze residual stresses were those by Kruth et al [32], Carter et al [78], Zhang et al [79], Abe et al [55], Bo et al [80], Shiomi et al [81], Yasa and Kruth [82] and Mumtaz and Hopkinson [83]. Kruth et al and Carter et al explored the effects on the thermal stresses of modifying the length and orientation of the laser scan vectors, performing pre-and post-scanning and island scanning, varying the layer thickness, heating the base plate and heat treating the final parts.…”

Research on the application of additive manufacturing technology in the design and manufacture of logging tools

“…In 2021, Feng.Y.R, elaborated the basic additive manufacturing process in the literature [10], and made a comprehensive summary of the application of domestic 3D metal printing technology in the development of petroleum logging instruments, and studied the application in threading curved holes, turbines and structural improvement. Based on the research status of metal additive manufacturing technology, material and structure, Zhang C R analyzed the current research hotspots and development trends in literature [11]. In literature [12], Liu B Y.etc reviewed the research progress of structural topology optimization design for metal-additive manufacturing technology, from the perspective of metal-additive manufacturing constraints, the topology optimization methods considering geometric constraints, forming constraints and material performance constraints are summarized.…”

Overhanging Features and the SLM/DMLS Residual Stresses Problem: Review and Future Research Need

“…While this is the most common technique, besides post-processing, to optimize parts, it depends mostly on the experience and intuition of the user and is usually not applicable to general problems using SLM/DMLS. While many case studies and part-and machine-specific solutions have been published, the best documented and most widely-cited solutions that analyze residual stresses were those by Kruth et al [32], Carter et al [78], Zhang et al [79], Abe et al [55], Bo et al [80], Shiomi et al [81], Yasa and Kruth [82] and Mumtaz and Hopkinson [83].…”