scholarly journals Geometrical, microstructural, and mechanical properties of curved-surface AlSi10Mg parts fabricated by powder bed fusion additive manufacturing

2021 ◽  
Vol 198 ◽  
pp. 109360
Author(s):  
Yue Zhou ◽  
Fuda Ning ◽  
Pu Zhang ◽  
Anju Sharma
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Curved Surface ◽  
Powder Bed Fusion ◽  
Powder Bed

Effects of Build Orientation on Mechanical Properties of Curved-Surface AlSi10Mg Alloy Fabricated by Powder Bed Fusion Additive Manufacturing

2020 ◽  
Author(s):  
Yue Zhou ◽  
Fuda Ning
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Lattice Structure ◽  
Curved Surface ◽  
Thin Wall ◽  
Variable Cross ◽  
Curved Surfaces ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Build Orientation

Abstract AlSi10Mg alloy has been widely used in the aerospace and automotive industries due to its superior physical and mechanical properties. Most AlSi10Mg components possess complicated-geometrical characteristics, such as planar thin wall, lattice structure, curved surface, etc. In recent years, laser-based powder bed fusion (PBF) has emerged as a promising additive manufacturing technique to produce complex AlSi10Mg alloy parts with a high resolution. PBF of curved-surface components exhibit varied heat transfer conditions, challenging post-fabrication processes, and intricate force conditions during mechanical testing owing to their structural inflections and variable cross-sections. Thus, the mechanical properties of the as-built AlSi10Mg parts with curved surfaces should be comprehensively understood to facilitate the adoption of PBF-built curved-surface AlSi10Mg parts in practical engineering applications. This paper systematically investigated the effects of build orientation on the tensile property and microhardness of the PBF-built AlSi10Mg parts with curved surfaces. The results showed that both bending stress and stretching stress contributed to the overall tensile stress of the curved-surface tensile specimens, and the failure always occurred at the peak/valley locations of the sine curved surface due to the largest bending moment. Meanwhile, the ultimate tensile strength increased with the build orientation varying from 60° to 90°. In addition, the curvatures C2 and C4 presented the lowest microhardness while C1 and C5 showed the highest one.

A printability assessment framework for fabricating low variability nickel-niobium parts using laser powder bed fusion additive manufacturing

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Bing Zhang ◽  
Raiyan Seede ◽  
Austin Whitt ◽  
David Shoukr ◽  
Xueqin Huang ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Uncertainty Quantification ◽  
Process Optimization ◽  
Powder Bed Fusion ◽  
Assessment Framework ◽  
Laser Powder Bed Fusion ◽  
Content Type ◽  
Powder Bed ◽  
Analytical Thermal Model

Purpose There is recent emphasis on designing new materials and alloys specifically for metal additive manufacturing (AM) processes, in contrast to AM of existing alloys that were developed for other traditional manufacturing methods involving considerably different physics. Process optimization to determine processing recipes for newly developed materials is expensive and time-consuming. The purpose of the current work is to use a systematic printability assessment framework developed by the co-authors to determine windows of processing parameters to print defect-free parts from a binary nickel-niobium alloy (NiNb5) using laser powder bed fusion (LPBF) metal AM. Design/methodology/approach The printability assessment framework integrates analytical thermal modeling, uncertainty quantification and experimental characterization to determine processing windows for NiNb5 in an accelerated fashion. Test coupons and mechanical test samples were fabricated on a ProX 200 commercial LPBF system. A series of density, microstructure and mechanical property characterization was conducted to validate the proposed framework. Findings Near fully-dense parts with more than 99% density were successfully printed using the proposed framework. Furthermore, the mechanical properties of as-printed parts showed low variability, good tensile strength of up to 662 MPa and tensile ductility 51% higher than what has been reported in the literature. Originality/value Although many literature studies investigate process optimization for metal AM, there is a lack of a systematic printability assessment framework to determine manufacturing process parameters for newly designed AM materials in an accelerated fashion. Moreover, the majority of existing process optimization approaches involve either time- and cost-intensive experimental campaigns or require the use of proprietary computational materials codes. Through the use of a readily accessible analytical thermal model coupled with statistical calibration and uncertainty quantification techniques, the proposed framework achieves both efficiency and accessibility to the user. Furthermore, this study demonstrates that following this framework results in printed parts with low degrees of variability in their mechanical properties.

scholarly journals On the Impact of Build Envelope Sizes on E-PBF Processed Pure Iron

2021 ◽  
Author(s):  
C. J. J. Torrent ◽  
P. Krooß ◽  
T. Niendorf
Keyword(s):  
Mechanical Properties ◽  
Electron Beam ◽  
Additive Manufacturing ◽  
Thermal History ◽  
Powder Bed Fusion ◽  
Parameter Setting ◽  
Powder Bed ◽  
History Of ◽  
Specific Temperature ◽  
The Impact

AbstractIn additive manufacturing, the thermal history of a part determines its final microstructural and mechanical properties. The factors leading to a specific temperature profile are diverse. For the integrity of a parameter setting established, periphery variations must also be considered. In the present study, iron was processed by electron beam powder bed fusion. Parts realized by two process runs featuring different build plate sizes were analyzed. It is shown that the process temperature differs significantly, eventually affecting the properties of the processed parts.

Quasicrystalline Composites by Additive Manufacturing

2019 ◽  
Vol 818 ◽  
pp. 72-76 ◽  
Author(s):  
Konda Gokuldoss Prashanth ◽  
Sergio Scudino
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Complex Shape ◽  
Powder Bed Fusion ◽  
Laser Melting ◽  
Powder Bed ◽  
Novel Materials ◽  
Tunable Properties

Laser based powder bed fusion (LBPF) or selective laser melting (SLM) is making a leap march towards fabricating novel materials with improved functionalities. An attempt has been made here to fabricate hard quasicrystalline composites via SLM, which demonstrates that the process parameters can be used to vary the phases in the composites. The mechanical properties of the composite depend on their constituents and hence can be varied by varying the process parameters. The results show that SLM not only produces parts with improved functionalities and complex shape but also leads to defined phases and tunable properties.

Development and experimental study of an automated laser-foil-printing additive manufacturing system

2022 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Chia-Hung Hung ◽  
Tunay Turk ◽  
M. Hossein Sehhat ◽  
Ming C. Leu
Keyword(s):  
Mechanical Properties ◽  
Experimental Study ◽  
Additive Manufacturing ◽  
Mechanical Strength ◽  
Automated System ◽  
304L Stainless Steel ◽  
Powder Bed Fusion ◽  
Content Type ◽  
Powder Bed ◽  
Manufacturing Methods

Purpose This paper aims to present the development and experimental study of a fully automated system using a novel laser additive manufacturing technology called laser foil printing (LFP), to fabricate metal parts layer by layer. The mechanical properties of parts fabricated with this novel system are compared with those of comparable methodologies to emphasize the suitability of this process. Design/methodology/approach Test specimens and parts with different geometries were fabricated from 304L stainless steel foil using an automated LFP system. The dimensions of the fabricated parts were measured, and the mechanical properties of the test specimens were characterized in terms of mechanical strength and elongation. Findings The properties of parts fabricated with the automated LFP system were compared with those of parts fabricated with the powder bed fusion additive manufacturing methods. The mechanical strength is higher than those of parts fabricated by the laser powder bed fusion and directed energy deposition technologies. Originality/value To the best knowledge of authors, this is the first time a fully automated LFP system has been developed and the properties of its fabricated parts were compared with other additive manufacturing methods for evaluation.

Effect of post-processing on microstructure and mechanical properties of Alloy 718 fabricated using powder bed fusion additive manufacturing processes

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Sareh Götelid ◽  
Taoran Ma ◽  
Christophe Lyphout ◽  
Jesper Vang ◽  
Emil Stålnacke ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Additive Manufacturing ◽  
Residual Stresses ◽  
Design Methodology ◽  
Hot Isostatic Pressing ◽  
Powder Bed Fusion ◽  
Content Type ◽  
Powder Bed ◽  
Nickel Based Superalloy ◽  
Compressive Stresses

Purpose This study aims to investigate additive manufacturing of nickel-based superalloy IN718 made by powder bed fusion processes: powder bed fusion laser beam (PBF-LB) and powder bed fusion electron beam (PBF-EB). Design/methodology/approach This work has focused on the influence of building methods and post-fabrication processes on the final part properties, including microstructure, surface quality, residual stresses and mechanical properties. Findings PBF-LB produced a much smoother surface. Blasting and shot peening (SP) reduced the roughness even more but did not affect the PBF-EB surface finish as much. As-printed PBF-EB parts have low residual stresses in all directions, whereas it was much higher for PBF-LB. However, heat treatment removed the stresses and SP created compressive stresses for samples from both PBF processes. The standard Arcam process parameter for PBF-EB for IN718 is not fully optimized, which leads to porosity and inferior mechanical properties. However, impact toughness after hot isostatic pressing was surprisingly high. Originality/value The two processes gave different results and also responses to post-treatments, which could be of advantage or disadvantage for different applications. Suggestions for improving the properties of parts produced by each method are presented.

Evaluation of the Material Properties of the Ti and CoCr Alloys Prepared by Laser Powder Bed Fusion

2020 ◽  
Vol 985 ◽  
pp. 223-228
Author(s):  
Jana Bidulská ◽  
Róbert Bidulský ◽  
Patrik Petrouse ◽  
Tibor Kvačkaj ◽  
Marco Actis Grande ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Image Analysis ◽  
Additive Manufacturing ◽  
Material Properties ◽  
Ti6al4v Alloy ◽  
Homogeneous Distribution ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Quantitative Image

The main aim of the present paper is evaluated the mechanical properties, microstructures and porosity of Ti6Al4V and CoCrW alloys produced by Laser Powder Bed Fusion (L-PBF) as an additive manufacturing (AM) technology. The mechanical properties were follows: For Ti6Al4V alloy the UTS was 1180 MPa; the YS was in the range <600; 745 MPa>. For CoCrW alloys, the UTS were in range <750; 950 MPa> and YS was in range <400; 500>. Evaluation of porosity was realized on non-etched samples using by quantitative image analysis in order to describe the dimensional and morphological porosity characteristics. The pores in the Ti6Al4V alloy showed homogeneous distribution without significant large pores.

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