Surface finish in laser solid freeform fabrication of an AISI 303L stainless steel thin wall

Alimardani, Masoud; Fallah, Vahid; Iravani-Tabrizipour, Mehrdad; Khajepour, Amir

doi:10.1016/j.jmatprotec.2011.08.012

Cited by 37 publications

(10 citation statements)

References 23 publications

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“…A melt-pool enlargement was shown to be the main contributor to optimum surface smoothness. It was also shown by (Alimardani et al, 2012) that an increase of the scanning speed and a real-time control of the melt-pool dimension and temperature could significantly improve surface finish.…”

Section: Introductionmentioning

confidence: 99%

Influence of various process conditions on surface finishes induced by the direct metal deposition laser technique on a Ti–6Al–4V alloy

Gharbi

Peyre

Gorny

et al. 2013

Journal of Materials Processing Technology

143

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is an open access repository that collects the work of Arts et Métiers ParisTech researchers and makes it freely available over the web where possible. a b s t r a c tThe direct metal deposition (DMD) with laser is a free-form metal deposition process for manufacturing dense pieces, which allows generating a prototype or small series of near net-shape structures. One of the most critical issues is that produced pieces have a deleterious surface finish which systematically requires post machining steps. This problem has never been fully addressed before. The present work describes investigations on the DMD process, using an Yb-YAG disk laser, and a widely used titanium alloy (Ti-6Al-4V) to understand the influence of the main process parameters on the surface finish quality. The focus of our work was: (1) to understand the physical mechanisms responsible for deleterious surface finishes, (2) to propose different experimental solutions for improving surface finish.In order to understand the physical mechanisms responsible for deleterious surface finishes, we have carried out: (1) a precise characterization of the laser beam and the powder stream; (2) a large number of multi-layered walls using different process parameters (P(W), V(m/min), D m (g/min), Gaussian or uniform beam distribution); (3) a real time fast camera analysis of melt pool dynamics and melt-pool -powder stream coupling; (4) a characterization of wall morphologies versus process parameters using 2D and 3D profilometry.The results confirm that surface degradation depends on two distinct aspects: the sticking of nonmelted or partially melted particles on the free surfaces, and the formation of menisci with more or less pronounced curvature radii. Among other aspects, a reduction of layer thickness and an increase of melt-pool volumes to favor re-melting processes are shown to have a beneficial effect on roughness parameters. Last, a simple analytical model was proposed to correlate melt-pool geometries to resulting surface finishes.

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Section: Introductionmentioning

confidence: 99%

Influence of various process conditions on surface finishes induced by the direct metal deposition laser technique on a Ti–6Al–4V alloy

Gharbi

Peyre

Gorny

et al. 2013

Journal of Materials Processing Technology

143

View full text Add to dashboard Cite

show abstract

“…According to their analysis, surface roughness decreased linearly with increasing laser power, thereby improving the surface finish. A study by Alimardani et al [43] on the effect of scanning speed and melt pool dimension increase on surface finish quality showed that the melt pool geometry control and temperature had a positive influence on surface finish.…”

Section: Laser Powermentioning

confidence: 99%

Laser Engineering Net Shaping Method in the Area of Development of Functionally Graded Materials (FGMs) for Aero Engine Applications - A Review

Popoola¹,

Farotade²,

Fatoba³

et al. 2016

Fiber Laser

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Modern aero engine components are subjected to extreme conditions were high wear rate, excessive fatigue cycles, and severe thermal attack are inevitable. These aggressive conditions reduce the service life of components. Its generic effect is magnified in the light of understanding the fact that aero engine parts are highly sensitive to functional and dimensional precision therefore, repair and replacement are great factors that promote downtime during operation. Hard thermal barrier coatings have been used in recent times due to their optimized properties for maximum load bearing proficiency with high temperature capability to meet performance and durability required. Nevertheless, less emphasis is being given to the coating-substrate interaction. Functionally graded structures have better synergy and flexibility in composition than coatings, giving rise to controlled microstructure and improved properties in withstanding acute state of affairs. Such materials can be fabricated using Laser Engineered Net Shaping LENS™ , a laser-based additive manufacturing technique. LENS™ offers a great deal in rapid prototyping, repair, and fabrication of three-dimensional dense structures with superior properties in comparison with traditionally fabricated structures. The manufacture of aero engine components with functionally graded materials, using LENS™, can absolutely mitigate the nuisance of buy-to-fly ratio, lost time in repair and maintenance, and maximize controlled dimension and multi-geometric properties, enhanced wear resistance, and high temperature strength. This review presents an extensive contribution in terms of insightful understanding of processing parameters and their interactions on fabrication of functionally graded stainless steel, which definitely influence the final product quality.

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“…During DLF, the injection powders are heated and melted rapidly when the focused laser passes this position, and then the deposited material at this position cools rapidly. Alimardani et al (2012) has demonstrated that the rapid heating and cooling rates impose a high risk of cracking during DLF. For a certain position of the previous deposited areas, it will be reheated or remelted repeatedly during laser depositing other melted tracks on x-y plane or cladding layers along z direction and cool as the laser beam moves away.…”

Section: Effect Of Processing Characteristics Of Dlfmentioning

confidence: 99%

Cracking behavior and control of Rene 104 superalloy produced by direct laser fabrication

Yang

Wang

et al. 2015

Journal of Materials Processing Technology

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Surface finish in laser solid freeform fabrication of an AISI 303L stainless steel thin wall

Cited by 37 publications

References 23 publications

Influence of various process conditions on surface finishes induced by the direct metal deposition laser technique on a Ti–6Al–4V alloy

Influence of various process conditions on surface finishes induced by the direct metal deposition laser technique on a Ti–6Al–4V alloy

Laser Engineering Net Shaping Method in the Area of Development of Functionally Graded Materials (FGMs) for Aero Engine Applications - A Review

Cracking behavior and control of Rene 104 superalloy produced by direct laser fabrication

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