Understanding melt pool characteristics in laser powder bed fusion: An overview of single- and multi-track melt pools for process optimization

Wang, Jincheng; Zhu, Rui; Liu, Yujing; Zhang, Lai-Chang

doi:10.1016/j.apmate.2023.100137

Cited by 97 publications

(37 citation statements)

References 193 publications

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“…Due to the focused laser heating on the powder bed, the L-PBF process bears risks of various defects that are brought about by its instability [184,185]. The formation of spatters, which is an inevitable by-product of the L-PBF process, is the main reason for powder degradation during reuse [186].…”

Section: Powder Degradation During Powder Reusementioning

confidence: 99%

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Sun,

Chen,

Liu

et al. 2023

Int. J. Extrem. Manuf.

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Laser powder bed fusion (L-PBF) has attracted significant attention since its inception, providing unprecedented advantages to fabricate metallic components with complex geometry. The quality and performance of as-printed alloys is an intricate function consisting of numerous factors linking the feedstock powders, manufacturing, and post-treatment. As the starting materials, powders play a critical role in influencing the printing consistency, total fabrication cost, and mechanical properties. In consideration of its importance for L-PBF, the present review aims to review the recent progress on metallic powders for L-PBF focusing on powder characterization, powder fabrication, and powder reuse. The methods of powder characterization and fabrication were presented in the beginning by analyzing the principles and corresponding advantages and limitations. Subsequently, the effect of powder reuse on the powder characteristics and mechanical performance of L-PBF parts is analyzed focusing on steels, nickel-based superalloys, Ti and Ti alloys, and Al alloys. The evolution trend of powders and as-printed parts varies for different alloy systems based on the existing studies, which makes the proposal of a unified reuse protocol infeasible. Finally, perspectives are presented to cater to the increasing applications of AM technologies for future investigations. The present state-of-the-art work can pave the way for the broad industrial applications of L-PBF by enhancing printing consistency and reducing the total cost from the perspective of powders.

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Section: Powder Degradation During Powder Reusementioning

confidence: 99%

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Sun,

Chen,

Liu

et al. 2023

Int. J. Extrem. Manuf.

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“…In 2016, Montani et al [22] conducted the pioneering investigation into the feasibility of pure Zn prepared by LPBF and observed a relative density of only 88% due to its susceptibility to evaporation during rapid solidification caused by its low melting and boiling points, resulting in inadequate densification. Subsequently, numerous works have been dedicated to fabricating highly dense Zn samples through LPBF equipment modification [23], meticulous monitoring of the printing process [24], and optimization of process parameters to mitigate evaporation [25,26]. For instance, Qin et al [27] achieved a relative density exceeding 99% in LPBF-printed pure Zn samples through optimizing gas protection and laser energy input.…”

Section: Introductionmentioning

confidence: 99%

Role of heterogenous microstructure and deformation behavior in achieving superior strength-ductility synergy in zinc fabricated via laser powder bed fusion

Dong,

Han,

Zhao

et al. 2024

Int. J. Extrem. Manuf.

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Zinc (Zn) is considered a promising biodegradable metal for implant applications due to its appropriate degradability and favorable osteogenesis properties. In this work, laser powder bed fusion (LPBF) additive manufacturing was employed to fabricate pure Zn with a heterogenous microstructure and exceptional strength-ductility synergy. An optimized processing window of LPBF was established for printing Zn samples with relative densities greater than 99% using a laser power range of 80–90 W and a scanning speed of 900 mm/s. The Zn sample printed with a power of 80 W at a speed of 900 mm/s exhibited a hierarchical heterogenous microstructure consisting of millimeter-scale molten pool boundaries, micrometer-scale bimodal grains, and nanometer-scale pre-existing dislocations, due to rapid cooling rates and significant thermal gradients formed in the molten pools. The printed sample exhibited the highest ductility of ~12.1% among all reported LPBF-printed pure Zn to date with appreciable ultimate tensile strength (~128.7 MPa). Such superior strength-ductility synergy can be attributed to the presence of multiple deformation mechanisms that are primarily governed by heterogeneous deformation-induced hardening resulting from the alternatively arrangement of bimodal Zn grains with pre-existing dislocations. Additionally, continuous strain hardening was facilitated through the interactions between deformation twins, grains and dislocations as strain accumulated, further contributing to the superior strength-ductility synergy. These findings provide valuable insights into the deformation behavior and mechanisms underlying exceptional mechanical properties of LPBF-printed Zn and its alloys for implant applications.

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“…26,27 The evolution of additive manufacturing (AM) has revolutionized orthopedic implant production. 28 In comparison to conventional manufacturing techniques, AM presents advantages in personalized customization, the ability to handle intricate geometries and design optimization 29 while also reducing production time and costs. 30 Particularly in the fabrication of porous structures, AM proves notably advantageous, enabling the swift translation of computer-aided design and computer-aided manufacturing (CAD/CAM) files into physical objects with reproducibility.…”

Section: Introductionmentioning

confidence: 99%

Bamboo-Inspired Porous Scaffolds for Advanced Orthopedic Implants: Design, Mechanical Properties, and Fluid Characteristics

Chen,

Liu,

et al. 2024

ACS Biomater. Sci. Eng.

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In orthopedic implant development, incorporating a porous structure into implants can reduce the elastic modulus to prevent stress shielding but may compromise yield strength, risking prosthesis fracture. Bamboo’s natural structure, with its exceptional strength-to-weight ratio, serves as inspiration. This study explores biomimicry using bamboo-inspired porous scaffolds (BISs) resembling cortical bone, assessing their mechanical properties and fluid characteristics. The BIS consists of two 2D units controlled by structural parameters α and β. The mechanical properties, failure mechanisms, energy absorption, and predictive performance are investigated. BIS exhibits mechanical properties equivalent to those of natural bone. Specifically, α at 4/3 and β at 2/3 yield superior mechanical properties, and the destruction mechanism occurs layer by layer. Besides, the Gibson–Ashby models with different parameters are established to predict mechanical properties. Fluid dynamics analysis reveals two high-flow channels in BISs, enhancing nutrient delivery through high-flow channels and promoting cell adhesion and proliferation in low-flow regions. For wall shear stress below 30 mPa (ideal for cell growth), α at 4/3 achieves the highest percentage (99.04%), and β at 2/3 achieves 98.46%. Permeability in all structural parameters surpasses that of human bone. Enhanced performance of orthopedic implants through a bionic approach that enables the creation of pore structures suitable for implants.

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Understanding melt pool characteristics in laser powder bed fusion: An overview of single- and multi-track melt pools for process optimization

Cited by 97 publications

References 193 publications

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Characterization, preparation, and reuse of metallic powders for laser powder bed fusion: a review

Role of heterogenous microstructure and deformation behavior in achieving superior strength-ductility synergy in zinc fabricated via laser powder bed fusion

Bamboo-Inspired Porous Scaffolds for Advanced Orthopedic Implants: Design, Mechanical Properties, and Fluid Characteristics

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