scholarly journals Improving surface quality in selective laser melting based tool making

2021 ◽  
Author(s):  
Filippo Simoni ◽  
Andrea Huxol ◽  
Franz-Josef Villmer
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Surface Quality ◽  
Selective Laser Melting ◽  
Melting Process ◽  
Laser Remelting ◽  
Laser Melting ◽  
Great Cost ◽  
Starting Point ◽  
Processing Techniques

AbstractIn the last years, Additive Manufacturing, thanks to its capability of continuous improvements in performance and cost-efficiency, was able to partly replace and redefine well-established manufacturing processes. This research is based on the idea to achieve great cost and operational benefits especially in the field of tool making for injection molding by combining traditional and additive manufacturing in one process chain. Special attention is given to the surface quality in terms of surface roughness and its optimization directly in the Selective Laser Melting process. This article presents the possibility for a remelting process of the SLM parts as a way to optimize the surfaces of the produced parts. The influence of laser remelting on the surface roughness of the parts is analyzed while varying machine parameters like laser power and scan settings. Laser remelting with optimized parameter settings considerably improves the surface quality of SLM parts and is a great starting point for further post-processing techniques, which require a low initial value of surface roughness.

scholarly journals Surface Quality Research for Selective Laser Melting of Ti-6Al-4V Alloy

2016 ◽  
Vol 61 (3) ◽  
pp. 1291-1296 ◽  
Author(s):  
M. Król ◽  
T. Tański
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Surface Quality ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Scanning Speed ◽  
Innovative Technology ◽  
Metal Powders ◽  
Laser Melting ◽  
Influence Of Process Parameters

Abstract One of the innovative technology of producing the components is Selective Laser Melting (SLM) belongs to additive manufacturing techniques. SLM technology has already been successfully applied in the automotive, aerospace and medical industries. Despite progress in material flexibility and mechanical performances, relatively poor surface finish still presents a significant weakness in the SLM process. The scope of the present article is the study the influence of selective laser melting parameters such as laser power, scanning speed, exposure time and hatch spacing through additive manufacturing as well as the orientation of the model corresponding to the laser beam on the surface characteristic of the components made from Ti-6Al-4V alloy. By using optimized process parameters, a low surface roughness can be obtained. In research, the machine for the selective laser melting of metal powders Renishaw AM 125 device was used. Based on experiment plan, 32 models were produced, which were examined to define the surface roughness and thus represent an influence of process parameters and the orientation on the model surface quality. The article discusses the fundamental factors determining the roughness that gives invaluable knowledge to improve the surface quality of SLM parts.

scholarly journals Directionally-Dependent Mechanical Properties of Ti6Al4V Manufactured by Electron Beam Melting (EBM) and Selective Laser Melting (SLM)

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3603
Author(s):  
Tim Pasang ◽  
Benny Tavlovich ◽  
Omry Yannay ◽  
Ben Jakson ◽  
Mike Fry ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Tensile Strength ◽  
Electron Beam ◽  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Electron Beam Melting ◽  
Rolling Direction ◽  
Laser Melting ◽  
Plate Rolling

An investigation of mechanical properties of Ti6Al4V produced by additive manufacturing (AM) in the as-printed condition have been conducted and compared with wrought alloys. The AM samples were built by Selective Laser Melting (SLM) and Electron Beam Melting (EBM) in 0°, 45° and 90°—relative to horizontal direction. Similarly, the wrought samples were also cut and tested in the same directions relative to the plate rolling direction. The microstructures of the samples were significantly different on all samples. α′ martensite was observed on the SLM, acicular α on EBM and combination of both on the wrought alloy. EBM samples had higher surface roughness (Ra) compared with both SLM and wrought alloy. SLM samples were comparatively harder than wrought alloy and EBM. Tensile strength of the wrought alloy was higher in all directions except for 45°, where SLM samples showed higher strength than both EBM and wrought alloy on that direction. The ductility of the wrought alloy was consistently higher than both SLM and EBM indicated by clear necking feature on the wrought alloy samples. Dimples were observed on all fracture surfaces.

Additive Manufacturing of Metals via Selective Laser Melting: Process Aspects and Material Developments

2015 ◽  
pp. 69-99 ◽  
Author(s):  
Jean-Pierre Kruth ◽  
Sasan Dadbakhsh ◽  
Bey Vrancken ◽  
Karolien Kempen ◽  
Jef Vleugels ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Melting Process ◽  
Laser Melting ◽  
Selective Laser Melting Process

scholarly journals Selective Laser Melting process simulation of open lattice cellular materials

2018 ◽  
Vol 188 ◽  
pp. 03019
Author(s):  
George Lampeas
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Process Simulation ◽  
Melting Process ◽  
Element Model ◽  
Cellular Materials ◽  
Laser Melting ◽  
Simulation Methodology ◽  
Efficient Simulation ◽  
Present Simulation

In the present paper an efficient simulation of an Additive Manufacturing process is presented. The analysis is aiming to quantify the relations between process parameters and material characteristics. The methodology is demonstrated in the fabrication of an open-lattice Body- Centred-Cubic (BCC) cellular core, produced by means of the Additive Manufacturing Selective Laser Melting method. The results of the developed finite element model are compared to experimental results demonstrating a successful validation of the simulation methodology. The results of the present simulation can be used as input for the prediction of the mechanical properties of the cellular materials under investigation.

scholarly journals Effect of Process Parameters on the Generated Surface Roughness of Down-Facing Surfaces in Selective Laser Melting

2019 ◽  
Vol 9 (6) ◽  
pp. 1256 ◽  
Author(s):  
Amal Charles ◽  
Ahmed Elkaseer ◽  
Lore Thijs ◽  
Veit Hagenmeyer ◽  
Steffen Scholz
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Process Models ◽  
Average Error ◽  
Lead Times ◽  
Laser Melting ◽  
Optimization Of Process Parameters ◽  
The Difference

Additive manufacturing provides a number of benefits in terms of infinite freedom to design complex parts and reduced lead-times while globally reducing the size of supply chains as it brings all production processes under one roof. However, additive manufacturing (AM) lags far behind conventional manufacturing in terms of surface quality. This proves a hindrance for many companies considering investment in AM. The aim of this work is to investigate the effect of varying process parameters on the resultant roughness of the down-facing surfaces in selective laser melting (SLM). A systematic experimental study was carried out and the effects of the interaction of the different parameters and their effect on the surface roughness (Sa) were analyzed. It was found that the interaction and interdependency between parameters were of greatest significance to the obtainable surface roughness, though their effects vary greatly depending on the applied levels. This behavior was mainly attributed to the difference in energy absorbed by the powder. Predictive process models for optimization of process parameters for minimizing the obtained Sa in 45° and 35° down-facing surface, individually, were achieved with average error percentages of 5% and 6.3%, respectively, however further investigation is still warranted.

scholarly journals Experimental investigation of effect of printing direction and surface roughness on the mechanical properties of AlSi10Mg-alloy produced by selective laser melting

2021 ◽  
Author(s):  
Dmitry Vysochinskiy ◽  
Naureen Akhtar ◽  
Tord Nordmo ◽  
Mathias Rabjerg Strand ◽  
Adrian Vyssios ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Heat Treatment ◽  
Surface Roughness ◽  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Material Strength ◽  
Laser Melting ◽  
Tension Tests ◽  
Printing Direction ◽  
Effect Of Surface

The additive manufacturing has initially gained popularity for production of non-loadbearing parts and components or in the fields where the material strength and ductility are less important such as modelling and rapid prototyping. But as the technology develops, availability of metal additive manufacturing naturally dictates the desire to use the produced components in load-bearing parts. This requires not-only a thorough documentation on the mechanical properties but also additional and independent research to learn the expected level of variation of the mechanical properties and what factors affect them. The presented paper investigates strength, ductility, hardness, and microstructure of the AlSi10Mg alloy produced by the selective laser melting (SLM). The mechanical properties were determined through a series of uniaxial tension tests and supplementary hardness tests and rationalized with the microstructure evolution with regard to printing direction and heat treatment. The paper also addresses the effect of surface roughness on the mechanical properties of the material, by comparing the machined and net shape tension samples. As expected, the as-manufactured AlSi10Mg-alloy appears to be a semi-brittle alloy, but its microstructure can be altered, and ductility increased by a proper heat-treatment. The effect of surface layer removal on the measured mechanical properties is of particular interest.

Investigation of selective laser melting process for Cu-5Sn alloy on surface roughness, microstructure and mechanical property

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Peng Yang ◽  
Dingyong He ◽  
Zengjie Wang ◽  
Zhen Tan ◽  
Hanguang Fu ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Mechanical Property ◽  
Surface Roughness ◽  
Selective Laser Melting ◽  
High Strength ◽  
Melting Process ◽  
Scanning Speed ◽  
Laser Melting ◽  
Forming Process ◽  
Content Type

Purpose In this research, the highly dense bulk Cu-5Sn alloy specimens were fabricated using selective laser melting (SLM). This study aims to establish the relationship between laser power (LP), scanning speed (SS) and hatch space (HS) with surface roughness (Ra) and density. To obtain Cu-5Sn alloy formed parts with high strength and low surface roughness. The microstructure and mechanical properties of SLMed Cu-5Sn were investigated. Design/methodology/approach The relative density (RD) was optimized using the response surface method (RSM) and analysis of variance. First, the Ra of SLMed formed specimens was studied to optimize the forming process parameters with a good surface. Then, the dense specimens were studied by ANOVA and the RSM to obtain dense specimens for mechanical property analysis. Findings Dense specimens were obtained by RSM and ANOVA. The tensile properties were compared with the casted specimens. The yield and ultimate strengths increased from 71 and 131 MPa for the cast specimens to 334 and 489 MPa for the SLMed specimens, respectively. The ductility increased significantly from 11% to 23%, due to the refined microstructure of the SLMed specimens, as well as the formation of many twin crystals. Originality/value The Ra, RD and mechanical properties of SLM specimens Cu-5Sn were systematically studied, and the influencing factors were analyzed together. This study provides a theoretical and practical example to improve the surface quality and RD.

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