Study on SLM fabrication of precision metal parts with overhanging structures

Wang, Di; Yang, Yongqiang; Zhang, Manhui; J, Lu; Liu, Ruicheng; Xiao, Dongming

doi:10.1109/isam.2013.6643532

“…Some studies that discuss the pros and cons of support structures to prevent damage in SLM/DMLS well were those performed by Hussein et al [21,22], Jhabvala et al [28], Matsumoto et al [18], Thomas and Bibb [29,30], Wang et al [31], Kruth et al [32] and Papadakis et al [33]. Data from several studies by Hussein et al [22], Kruth et al [32], Vora et al [34] and Patterson et al [35,36] suggested that the use of rigid support structures during SLM/DMLS for overhanging features may actually cause the residual stresses to be worse than if the overhang had no solid support during printing.…”

Section: Survey Of Previous Workmentioning

confidence: 99%

“…Other works that addressed the concern of overhanging feature stresses in SLM/DMLS were those by Wang et al [31,137,138], Cloots et al [139], Fox et al [140] and Kruth et al [141]. The focus of the studies performed by Wang et al was the design of curved overhanging parts and parts set at small angles, so designed that they did not need significant support material.…”

Section: Overhanging Feature Designmentioning

confidence: 99%

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

Patterson

¹

,

Messimer

²

,

Farrington

³

2017

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Abstract:A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce full-density metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of the literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging and design-of-experiments), support structure optimization and overhang feature design; approximately 143 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs and potential future research directions are discussed in-depth in light of the present review.

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“…Some studies that well discuss the pros and cons of support structures to prevent damage in SLM/DMLS were those performed by Hussein et al [21][22], Jhabvala et al [28], Matsumoto et al [18], Thomas and Bibb [29][30], Wang et al [31], Kruth et al 6 of 24 [32], and Papadakis et al [33]. Data from several studies by Hussein et al [22], Kruth et al [32], Vora et al [34] and Patterson et al [35][36] suggested that the use of rigid support structures during SLM/DMLS for overhanging features may actually cause the residual stresses to be worse than if the overhang had no solid support during printing.…”

Section: Figure 2 Stress Gradients In Single Layersmentioning

confidence: 99%

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

Patterson¹,

Messimer²,

Farrington³

2017

Preprint

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A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce fulldensity metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion, and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization, and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging, and design-of-experiments), support structure optimization, and overhang feature design; approximately 140 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs, and potential future research directions are discussed in-depth in light of the present review.

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“…In work discussed earlier, four studies discussing various aspects of overhanging structures were Other works that addressed the concern of overhanging feature stresses in SLM/DMLS were those by Wang et al [134][135][136], Cloots et al [137], Fox et al [138], and Kruth et al [139]. The focus of the studies performed by Wang et al was the design of curved overhanging parts and parts set at small angles, so designed that they did not need significant support material.…”

Section: Overhanging Feature Designmentioning

confidence: 99%

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

Patterson¹,

Messimer²,

Farrington³

2017

Preprint

View full text Add to dashboard Cite

A useful and increasingly common additive manufacturing (AM) process is the selective laser melting (SLM) or direct metal laser sintering (DMLS) process. SLM/DMLS can produce fulldensity metal parts from difficult materials, but it tends to suffer from severe residual stresses introduced during processing. This limits the usefulness and applicability of the process, particularly in the fabrication of parts with delicate overhanging and protruding features. The purpose of this study was to examine the current insight and progress made toward understanding and eliminating the problem in overhanging and protruding structures. To accomplish this, a survey of literature was undertaken, focusing on process modeling (general, heat transfer, stress and distortion, and material models), direct process control (input and environmental control, hardware-in-the-loop monitoring, parameter optimization, and post-processing), experiment development (methods for evaluation, optical and mechanical process monitoring, imaging, and design-of-experiments), support structure optimization, and overhang feature design; approximately 140 published works were examined. The major findings of this study were that a small minority of the literature on SLM/DMLS deals explicitly with the overhanging stress problem, but some fundamental work has been done on the problem. Implications, needs, and potential future research directions are discussed in-depth in light of the present review.

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Study on SLM fabrication of precision metal parts with overhanging structures

Cited by 15 publications

References 4 publications

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

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

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

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

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