A state-of-the-art direct metal laser sintering of Ti6Al4V and AlSi10Mg alloys: Surface roughness, tensile strength, fatigue strength and microstructure

2021 ◽  
Vol 143 ◽  
pp. 107366
Author(s):  
Kashif Ishfaq ◽  
Mirza Abdullah ◽  
Muhammad Arif Mahmood
Keyword(s):  
Surface Roughness ◽  
Tensile Strength ◽  
Fatigue Strength ◽  
State Of The Art ◽  
Laser Sintering ◽  
Direct Metal Laser Sintering

scholarly journals Mechanical Properties of Selective Laser Sintering Pure Titanium and Ti-6Al-4V, and Its Anisotropy

Materials ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5081
Author(s):  
Yuu Harada ◽  
Yoshiki Ishida ◽  
Daisuke Miura ◽  
Satoru Watanabe ◽  
Harumi Aoki ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Tensile Strength ◽  
Titanium Powder ◽  
Selective Laser Sintering ◽  
Pure Titanium ◽  
Color Difference ◽  
Laser Sintering ◽  
Great Performance ◽  
Dental Applications

Selective laser sintering (SLS) is being developed for dental applications. This study aimed to investigate the properties of Ti-6Al-4V and pure titanium specimens fabricated using the SLS process and compare them with casting specimens. Besides, the effect of the building direction on the properties of the SLS specimens was also investigated. Specimens were prepared by SLS using Ti-6Al-4V powder or pure titanium powder. Casting specimens were also prepared using Ti-6Al-4V alloys and pure titanium. The mechanical properties (tensile strength and elongation), physical properties (surface roughness, contact angle, and Vickers hardness); corrosion resistors (color difference and corrosion), and surface properties (chemical composition and surface observation) were examined. Both Ti-6Al-4V and pure titanium specimens produced using the SLS process had comparable or superior properties compared with casting specimens. In comparing the building directions, specimens fabricated horizontally to the printing platform showed the greatest tensile strength, and the surface roughness scanned in the horizontal direction to the platform showed the smallest. However, there was no significant effect on other properties. Thus, the SLS process with Ti-6Al-4V powder and pure titanium powder has great performance for the fabrication of dental prosthesis, and there is a possibility for it to take the place of conventional methods.

Microstructure and Tensile Strength of Rapid Manufacturing Parts

2014 ◽  
Vol 903 ◽  
pp. 114-117 ◽  
Author(s):  
Izhar Abd Aziz ◽  
Brian Gabbitas ◽  
Mark Stanford
Keyword(s):  
Mechanical Properties ◽  
Tensile Strength ◽  
Biomedical Applications ◽  
Bulk Material ◽  
Solidification Rate ◽  
Laser Sintering ◽  
Liquid Pool ◽  
Sintering Process ◽  
Direct Metal Laser Sintering ◽  
Production Route

The purpose of this work is to investigate the microstructure and tensile strength of Ti6Al4V pre-alloyed powders produced by a direct metal laser sintering technique. Traditionally, Ti6Al4V products for biomedical applications were produced through hot working or machining of wrought semi-finished products. A change in the production route for manufacturing Ti6Al4V products, from the more traditional methods to an additive manufacturing route, requires an investigation of microstructure and mechanical properties because these are strongly influenced by the production route. The microstructure obtained through rapid solidification during laser sintering shows a very fine α+β lamellar morphology. There is also evidence of martensite which was expected due to high solidification rate of the liquid pool from a temperature above the β-transus during the laser sintering process. Structurally, good mechanical properties which are comparable to the bulk material were obtained.

Rapid Manufacturing with Direct Metal Laser Sintering

2002 ◽  
Vol 758 ◽  
Author(s):  
J-E. Lind ◽  
J. Hanninen ◽  
J. Kotila ◽  
O. Nyrhila ◽  
T. Syvanen
Keyword(s):  
Surface Roughness ◽  
Layer Thickness ◽  
Process Development ◽  
Die Casting ◽  
Laser Sintering ◽  
Thin Layers ◽  
Rapid Manufacturing ◽  
Manufacturing Processes ◽  
Direct Metal Laser Sintering ◽  
Process Work

ABSTRACTThe term Rapid Manufacturing is today very often used as a substitute for Rapid Prototyping, because the manufacturing processes and materials have developed so much that the parts produced with the machines can even be used as functional production parts. For Direct Metal Laser Sintering (DMLS) this was enabled by the introduction of the powders for 20 micron layer thickness; steel-based powder in 2001 and bronze-based powder in 2002. Successful rapid manufacturing with DMLS does not only mean the reduction of layer thickness, but it is a sum of many factors that had to be optimized in order to make the process work with the 20 micron layer thickness: the metal powder behavior in very thin layers is not the same as with thicker layers, the demands for the support structures are higher and the possibility of using multiples of the layer thickness gives additional freedom. By optimizing the process parameters the UTS values for the steel-based powder increased up to 600 MPa and for the bronze-based powder up to 400 MPa. At the same time the surface roughness (Ra) values after shot peening were 3 microns and 2 microns, respectively. Although using thinner layers also increases the building time the advantage is gained in drastically reduced finishing times due to increased surface quality and detail resolution. Typical geometries produced by DMLS are difficult-to-manufacture components and components typically produced by P/M or even by die-casting. The paper covers the development aspects in both material and process development and also presents some realized case studies.

Mass Finishing of Parts Produced by Direct Metal Laser Sintering

Volume 3 ◽  
2004 ◽  
Author(s):  
A. Boschetto ◽  
F. Veniali ◽  
F. Miani
Keyword(s):  
Surface Roughness ◽  
Industrial Process ◽  
Mechanical Action ◽  
Laser Sintering ◽  
Main Process ◽  
Direct Metal Laser Sintering ◽  
Complicated Shape ◽  
Mass Finishing ◽  
Barrel Finishing ◽  
Established Technique

This paper presents some practical considerations on finishing of parts made by direct metal laser sintering (DMLS). The main process capabilities limitations of this promising rapid tooling technique are in fact in the surface roughness of the produced parts. This fact hinders the introduction of DMLS as a widely employed industrial process, especially for what concerns the production of moulds and inserts and allows their use only as preseries tools in injection moulding of plastics, since the requirements for preseries tools are worse than those needed during the process. Barrel finishing, in turn, is a well established technique to improve the roughness of parts of complicated shape by means of a soft mechanical action over the surface. The results herewith presented show that it is possible to achieve roughness of the order of 1 μm Ra even when starting from initial roughness of the order of 15 μm Ra, i.e. those typically attained by DMLS.

scholarly journals Sensitivity of direct metal laser sintering Maraging steel fatigue strength to build orientation and allowance for machining

2018 ◽  
Vol 42 (1) ◽  
pp. 374-386 ◽  
Author(s):  
Dario Croccolo ◽  
Massimiliano De Agostinis ◽  
Stefano Fini ◽  
Giorgio Olmi ◽  
Francesco Robusto ◽  
...  
Keyword(s):  
Fatigue Strength ◽  
Maraging Steel ◽  
Laser Sintering ◽  
Direct Metal Laser Sintering ◽  
Build Orientation

scholarly journals An Analysis of the Surface Geometric Structure and Geometric Accuracy of Cylindrical Gear Teeth Manufactured with the Direct Metal Laser Sintering (DMLS) Method

2019 ◽  
Author(s):  
Jadwiga Małgorzata Pisula ◽  
Grzegorz Budzik ◽  
Łukasz Przeszłowski
Keyword(s):  
Surface Roughness ◽  
Geometric Structure ◽  
Gear Tooth ◽  
Spur Gear ◽  
Laser Sintering ◽  
Tooth Surface ◽  
Direct Metal Laser Sintering ◽  
Cylindrical Gear ◽  
Sand Blasting ◽  
Gear Teeth

This paper presents findings concerning the accuracy of the geometry of cylindrical spur gear teeth manufactured with the direct metal laser sintering (DMLS) method. In addition, the results of the evaluation of the tooth surface geometric structure are presented in the form of selected two-dimensional and three-dimensional surface roughness parameters. An analysis of the accuracy of the fabricated gear teeth was performed after gear sand-blasting and gear tooth milling processes. Surface roughness was measured before and after sand-blasting and gear tooth milling. The test gear wheel was manufactured from GP1 high-chromium stainless steel on an EOS M270 machine.

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