Overview of finite elements simulation of temperature profile to estimate properties of materials 3D-printed by laser powder-bed fusion

2020 ◽  
Vol 29 (4) ◽  
pp. 048101
Author(s):  
Habimana Jean Willy ◽  
Xinwei Li ◽  
Yong Hao Tan ◽  
Zhe Chen ◽  
Mehmet Cagirici ◽  
...  
Keyword(s):  
Finite Elements ◽  
Temperature Profile ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
3D Printed ◽  
Properties Of Materials ◽  
Finite Elements Simulation

scholarly journals Gold, Silver, and Electrum Electroless Plating on Additively Manufactured Laser Powder-Bed Fusion AlSi10Mg Parts: A Review

Coatings ◽  
2021 ◽  
Vol 11 (4) ◽  
pp. 422
Author(s):  
Dana Ashkenazi ◽  
Alexandra Inberg ◽  
Yosi Shacham-Diamand ◽  
Adin Stern
Keyword(s):  
Additive Manufacturing ◽  
Low Cost ◽  
Ion Beam ◽  
Surface Finishing ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Finishing Process ◽  
Gold Silver ◽  
3D Printed

Additive manufacturing (AM) revolutionary technologies open new opportunities and challenges. They allow low-cost manufacturing of parts with complex geometries and short time-to-market of products that can be exclusively customized. Additive manufactured parts often need post-printing surface modification. This study aims to review novel environmental-friendly surface finishing process of 3D-printed AlSi10Mg parts by electroless deposition of gold, silver, and gold–silver alloy (e.g., electrum) and to propose a full process methodology suitable for effective metallization. This deposition technique is simple and low cost method, allowing the metallization of both conductive and insulating materials. The AlSi10Mg parts were produced by the additive manufacturing laser powder bed fusion (AM-LPBF) process. Gold, silver, and their alloys were chosen as coatings due to their esthetic appearance, good corrosion resistance, and excellent electrical and thermal conductivity. The metals were deposited on 3D-printed disk-shaped specimens at 80 and 90 °C using a dedicated surface activation method where special functionalization of the printed AlSi10Mg was performed to assure a uniform catalytic surface yielding a good adhesion of the deposited metal to the substrate. Various methods were used to examine the coating quality, including light microscopy, optical profilometry, XRD, X-ray fluorescence, SEM–energy-dispersive spectroscopy (EDS), focused ion beam (FIB)-SEM, and XPS analyses. The results indicate that the developed coatings yield satisfactory quality, and the suggested surface finishing process can be used for many AM products and applications.

scholarly journals Crystallization and Hardness Change of the Ti-Based Bulk Metallic Glass Manufactured by a Laser Powder Bed Fusion Process

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1049
Author(s):  
Ji-Hoon Jang ◽  
Hyung-Guin Kim ◽  
Hwi-Jun Kim ◽  
Dong-Geun Lee
Keyword(s):  
Energy Density ◽  
Amorphous Powder ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Scan Speed ◽  
3D Printed ◽  
Hardness Change ◽  
The Difference ◽  
Printing Processes

Ti-2.5Zr-5.0Hf-37.5Cu-7.5Ni-1.0Si-5.0Sn (at.%) BMG has been successfully manufactured in amorphous powder with a size of about 25 μm (D50). Using this amorphous powder, a Ti-based BMG was manufactured by an additive manufacturing process based on a laser powder bed fusion (LPBF) technique. In 3D printing processes using amorphous powders, it is necessary and important to understand the crystallization behavior due to the difference in energy density applied to the powders. An LPBF process has been carried out with various energy density conditions to minimize the inner defects and identify the sound mechanical properties of 3D-printed BMG parts. At the lowest energy density condition (3.0 J/mm3), the most pores were generated. Even if the same energy density (3.0 J/mm3) was applied, the rapid laser movement caused many pores to form inside the material. The relatively sound 3D-printed Ti-based BMG was successfully fabricated with a size of about 5 mm × 5 mm × 3 mm. Peaks at 41° and 44° showing crystallization were observed in all conditions. The higher the laser power was, the greater each peak intensity and the more crystallization (CuTi, Ti3Cu4, etc.) was present in the BMG, and the higher the scan speed, the more the internal defects were found.

scholarly journals Mechanics Modeling of Residual Stress Considering Effect of Preheating in Laser Powder Bed Fusion

2021 ◽  
Vol 5 (2) ◽  
pp. 46
Author(s):  
Elham Mirkoohi ◽  
Hong-Chuong Tran ◽  
Yu-Lung Lo ◽  
You-Cheng Chang ◽  
Hung-Yu Lin ◽  
...  
Keyword(s):  
Residual Stress ◽  
Thermal Stress ◽  
Temperature Gradient ◽  
Temperature Profile ◽  
Analytical Model ◽  
Kinematic Hardening ◽  
Process Conditions ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed

This study aimed at the investigation of the effect of substrate temperature on residual stress in laser powder bed fusion using a physics-based analytical model. In this study, an analytical model is proposed to predict the residual stress through the calculation of preheating affected temperature profile and thermal stress. The effect of preheating is super-positioned with initial temperature in the modeling of temperature profile using a moving heat source approach; the resultant temperature gradient is then employed to predict the thermal stress from a point body load approach. If the thermal stress exceeds the yield strength of the material, then the residual stress under cyclic heating and cooling will be calculated based on the incremental plasticity and kinematic hardening behavior of metal. IN718 is used as a material example to pursue this investigation. To validate the predicted residual stress, experimental measurements are conducted using X-ray diffraction on IN718 samples manufactured via laser powder bed fusion under different process conditions. Results showed that preheating of the substrate could reduce the residual stress in an additively manufactured part due to the reduction in temperature gradient and resultant shrinkage stresses. However, the excessive preheating could have an opposite impact on residual stress accumulation. Moreover, the results confirm that the proposed model is a valuable tool for the prediction of residual stress, eliminating the costly experiments and time-consuming finite element simulations.

scholarly journals The Average Grain Size and Grain Aspect Ratio in Metal Laser Powder Bed Fusion: Modeling and Experiment

2020 ◽  
Vol 4 (1) ◽  
pp. 25 ◽  
Author(s):  
Morgan Letenneur ◽  
Alena Kreitcberg ◽  
Vladimir Brailovski
Keyword(s):  
Grain Size ◽  
Aspect Ratio ◽  
Prediction Algorithm ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Melt Pool ◽  
Average Grain Size ◽  
Microstructure Prediction ◽  
3D Printed

The additive manufacturing (AM) process induces high uncertainty in the mechanical properties of 3D-printed parts, which represents one of the main barriers for a wider AM processes adoption. To address this problem, a new time-efficient microstructure prediction algorithm was proposed in this study for the laser powder bed fusion (LPBF) process. Based on a combination of the melt pool modeling and the design of experiment approaches, this algorithm was used to predict the microstructure (grain size/aspect ratio) of materials processed by an EOS M280 LPBF system, including Iron and IN625 alloys. This approach was successfully validated using experimental and literature data, thus demonstrating its potential efficiency for the optimization of different LPBF powders and systems.

scholarly journals Spreadability of Metal Powders for Laser-Powder Bed Fusion via Simple Image Processing Steps

Materials ◽  
2021 ◽  
Vol 15 (1) ◽  
pp. 205
Author(s):  
Cekdar Vakifahmetoglu ◽  
Beyza Hasdemir ◽  
Lisa Biasetto
Keyword(s):  
Image Processing ◽  
Processing Parameters ◽  
Angle Of Repose ◽  
Structural Defects ◽  
Powder Size ◽  
Powder Bed Fusion ◽  
Metal Powders ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
3D Printed

This paper investigates the spreadability of the spherical CoCrWMo powder for laser- powder bed fusion (PBF-LB) by using image processing algorithms coded in MATLAB. Besides, it also aims to examine the spreadability dependence with the other characteristics such as powder size distribution, apparent density, angle of repose. Powder blends in four different particle size distributions are prepared, characterized, and spreadability tests are performed with the PBF-LB. The results demonstrate that an increase in fine particle ratio by volume (below 10 µm) enhances the agglomeration and decreases the flowability, causing poor spreadability. These irregularities on the spread layers are quantified with simple illumination invariant analysis. A clear relation between powder spreadability and 3D printed structures properties in terms of residual porosity could not be defined since structural defects in 3D printed parts also depends on other processing parameters such as spatter formation or powder size over layer height ratio.

scholarly journals Manual polishing of 3D printed metals produced by laser powder bed fusion reduces biofilm formation

PLoS ONE ◽  
2019 ◽  
Vol 14 (2) ◽  
pp. e0212995 ◽  
Author(s):  
Marissa McGaffey ◽  
Alex zur Linden ◽  
Nathanael Bachynski ◽  
Michelle Oblak ◽  
Fiona James ◽  
...  
Keyword(s):  
Biofilm Formation ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
3D Printed

scholarly journals Mechanics Modeling of Residual Stress Considering Effect of Preheating in Laser Powder Bed Fusion

2021 ◽  
Author(s):  
Elham Mirkoohi ◽  
Hong-Chuong Tran ◽  
Yu-Lung Lo ◽  
You-Cheng Chang ◽  
Hung-Yu Lin ◽  
...  
Keyword(s):  
Residual Stress ◽  
Thermal Stress ◽  
Temperature Gradient ◽  
Temperature Profile ◽  
Analytical Model ◽  
Kinematic Hardening ◽  
Process Conditions ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed

This study aimed at the investigation of the effect of substrate preheating on residual stress in laser powder bed fusion using a physics-based analytical model. In this study, an analytical model is proposed to predict the residual stress through the calculation of preheating affected temperature profile and thermal stress. The effect of preheating is super-positioned with initial temperature in the modeling of temperature profile using a moving heat source approach; the resultant temperature gradient is then employed to predict the thermal stress from a point body load approach. If the thermal stress exceeds the yield strength of the material, then the residual stress under cyclic heating and cooling will be calculated based on the incremental plasticity and kinematic hardening behavior of metal. IN718 is used as a material example to pursue this investigation. To validate the predicted residual stress, experimental measurements are conducted using X-ray diffraction on IN718 samples manufactured via laser powder bed fusion under different process conditions. Results showed that preheating of the substrate could reduce the residual stress in an additively manufactured part due to the reduction in temperature gradient and resultant shrinkage stresses. However, the excessive preheating could have an opposite impact on residual stress accumulation. Moreover, the results confirm that the proposed model is a valuable tool for the prediction of residual stress- eliminating the costly experiments and time-consuming finite element simulations.

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