Selective laser melting of Inconel 718 under high laser power

Борисов, Е. В.; Popovich, Vera; Popovich, Anatoly; Sufiiarov, Vadim; Zhu, Jia–Ning; Starikov, Kirill

doi:10.1016/j.matpr.2020.01.571

Cited by 17 publications

(10 citation statements)

References 19 publications

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“…Pure nickel can be used as a material for processing with SLM; this precept was demonstrated by Yap Chor (2017). However, nickel-based alloys are most commonly used at an industrial level in the SLM process (Borisov et al, 2020;Chen et al, 2020c;Hassanin et al, 2020;Karia et al, 2017;Yang et al, 2019). Maraging steels (e.g.…”

Section: Nickel-based Alloysmentioning

confidence: 99%

Selective laser melting: lessons from medical devices industry and other applications

Fé-Perdomo

Ramos‐Grez

Beruvides³

et al. 2021

RPJ

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Purpose The purpose of this paper is to outline some key aspects such as material systems used, phenomenological and statistical process modeling, techniques applied to monitor the process and optimization approaches reported. All these need to be taken into account for the ongoing development of the SLM technique, particularly in health care applications. The outcomes from this review allow not only to summarize the main features of the process but also to collect a considerable amount of investigation effort so far achieved by the researcher community. Design/methodology/approach This paper reviews four significant areas of the selective laser melting (SLM) process of metallic systems within the scope of medical devices as follows: established and novel materials used, process modeling, process tracking and quality evaluation, and finally, the attempts for optimizing some process features such as surface roughness, porosity and mechanical properties. All the consulted literature has been highly detailed and discussed to understand the current and existing research gaps. Findings With this review, there is a prevailing need for further investigation on copper alloys, particularly when conformal cooling, antibacterial and antiviral properties are sought after. Moreover, artificial intelligence techniques for modeling and optimizing the SLM process parameters are still at a poor application level in this field. Furthermore, plenty of research work needs to be done to improve the existent online monitoring techniques. Research limitations/implications This review is limited only to the materials, models, monitoring methods, and optimization approaches reported on the SLM process for metallic systems, particularly those found in the health care arena. Practical implications SLM is a widely used metal additive manufacturing process due to the possibility of elaborating complex and customized tridimensional parts or components. It is corroborated that SLM produces minimal amounts of waste and enables optimal designs that allow considerable environmental advantages and promotes sustainability. Social implications The key perspectives about the applications of novel materials in the field of medicine are proposed. Originality/value The investigations about SLM contain an increasing amount of knowledge, motivated by the growing interest of the scientific community in this relatively young manufacturing process. This study can be seen as a compilation of relevant researches and findings in the field of the metal printing process.

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Section: Nickel-based Alloysmentioning

confidence: 99%

Selective laser melting: lessons from medical devices industry and other applications

Fé-Perdomo

Ramos‐Grez

Beruvides³

et al. 2021

RPJ

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“…For use in the flame tube zone, as well as in the hot part of the turbine, it is necessary to use alloys with a high content of the intermetallic phase. However, such alloys have a much lower weldability, which leads to the formation of defects when trying to obtain high-quality products by the SLM method due to significant temperature gradients during laser heating [15,16]. As one of the ways to prevent the formation of defects, heating of the working platform and the parts themselves is used in the process of manufacturing the part [15][16][17].…”

Section: Introductionmentioning

confidence: 99%

“…However, such alloys have a much lower weldability, which leads to the formation of defects when trying to obtain high-quality products by the SLM method due to significant temperature gradients during laser heating [15,16]. As one of the ways to prevent the formation of defects, heating of the working platform and the parts themselves is used in the process of manufacturing the part [15][16][17]. It helps to reduce thermal gradients and reduce thermal stress values.…”

Section: Introductionmentioning

confidence: 99%

heat treatment effect on the structure formation of directionally solidified nickel alloy after slm

Борисов

Starikov

Kim

et al. 2021

METAL 2021 Conference Proeedings

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“…The process is repeated layer by layer until the geometry of the part is obtained. The process melt pool dynamics involves the generation of high temperatures with fast cooling rates and highly localised thermal gradients that create a unique microstructure in the alloy, which can enhance mechanical properties [ 22 , 23 , 24 , 25 , 26 , 27 , 28 , 29 , 30 , 31 ].…”

Section: Introductionmentioning

confidence: 99%

“…A disadvantage often cited for LM-PBF alloys is the porosity and defects that develop in the alloy microstructure [ 25 , 26 , 28 ]. However, these can be minimized by the selection of specific process parameters together with post-processing treatments such as a hot isostatic pressing (HIP) which can eliminate most types of porosity below a certain size [ 32 ].…”

Section: Introductionmentioning

confidence: 99%

Machinability of INCONEL718 Alloy with a Porous Microstructure Produced by Laser Melting Powder Bed Fusion at Higher Energy Densities

Wood

Díaz-Álvarez

et al. 2020

Materials

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Products produced by additive manufacturing (AM) seek to exploit net shape manufacturing by eliminating or minimizing post-process stages such as machining. However, many applications which include turbo machinery components with tight dimensional tolerances and a smooth surface finish will require at least a light machine finishing stage. This paper investigates the machinability of the additively fabricated INCONEL718 (IN718) alloy produced by laser melting powder bed fusion (LM-PBF) with different levels of spherical porosity in the microstructure. The literature suggests that the band width for laser energy density, which combines the various scan process parameters to obtain a low spherical type porosity in the LM-PBF IN718 alloy (~1%), has wide breadth. With the increasing laser energy density and above a threshold, there is a rapid increase in the spherical pore size. In this paper, three tube samples each with different levels of spherical porosity were fabricated by varying the laser energy density for LM-PBF of the IN718 alloy within the stable and higher energy density range and the porosity measured. A low laser energy density was avoided due to balling up, which promotes highly irregular lack of fusion defects and poor consolidation within the alloy microstructure. An orthogonal turning test instrumented, with a three-component dynamometer to measure the cutting forces, was performed on AM produced IN718 tube samples under light cut conditions to simulate a finish machining process. The orthogonal turning tests were also performed on a tube sample obtained from the wrought extruded stock. The machining process parameters, which were studied include varying the cutting speed at three levels, at a fixed feed and under dry cut conditions for a short duration to avoid the tool wear. The results obtained were discussed and a notable finding was the higher rate of built-up-edge formation on the tool tip from the AM samples with a higher porosity and especially at a higher cutting speed. The paper also discusses the mechanisms that underpin the findings.

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Selective laser melting of Inconel 718 under high laser power

Cited by 17 publications

References 19 publications

Selective laser melting: lessons from medical devices industry and other applications

Selective laser melting: lessons from medical devices industry and other applications

heat treatment effect on the structure formation of directionally solidified nickel alloy after slm

Machinability of INCONEL718 Alloy with a Porous Microstructure Produced by Laser Melting Powder Bed Fusion at Higher Energy Densities

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