Resistance spot welding of additively manufactured maraging steels Part II: Failure behavior

2021 ◽  
pp. 1-31
Author(s):  
Cheng Luo ◽  
Yansong Zhang ◽  
Michael Oelscher ◽  
Yandong Shi ◽  
Niels Pasligh ◽  
...  
Keyword(s):  
Selective Laser Melting ◽  
Fracture Mode ◽  
Automotive Industry ◽  
Material Properties ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Melting Process ◽  
Spot Welds ◽  
Laser Melting ◽  
Maraging Steels

Abstract Application of maraging steels via selective laser melting process in the automotive industry was unavoidably involved in the resistance spot welding with conventional steels. Due to the rapid cooling rate of welding process, selective laser melted maraging steels with unique chemical components and stack microstructure could induced the different microstructural evolution, resulting in the complicated fracture behavior in the spot welds. This paper developed a FEA model to predict the fracture mode of spot welds of DP600 to maraging steel and the effect of test conditions and printing orientations were studied. A method was proposed to calculate the material properties of fusion zone by introducing the combined effect of melting DP600 and maraging steels via selective laser melting, resulting in the accurate prediction of fracture mode and strength of spot welds. An interlayer with lower strength was found around the fusion zone and the fracture path propagated in the region, resulting in the partial interfacial failure of spot welds. Meanwhile, the printing orientation had no significant effect on the fracture mode and strength of spot welds, but the different material properties of maraging steels could affect the fracture displacement of spot welds. These findings could pave a way to guide the application of maraging steels via selective laser melting process in multiple industries, especially in the automotive industry.

Resistance spot welding of additively manufactured maraging steels Part I: Nugget formation

2021 ◽  
pp. 1-34
Author(s):  
Cheng Luo ◽  
Yansong Zhang ◽  
Michael Oelscher ◽  
Yandong Shi ◽  
Niels Pasligh ◽  
...  
Keyword(s):  
Maraging Steel ◽  
Fusion Zone ◽  
Microstructural Evolution ◽  
Resistance Spot Welding ◽  
Spot Welding ◽  
Solidification Process ◽  
Melting Process ◽  
Rapid Solidification Process ◽  
Laser Melting ◽  
Resistance Spot

Abstract Application of additively manufactured steels is unavoidably involved in the resistance spot welding with conventionally manufactured steels. However, the microstructural evolution of an additive manufactured steel at high temperatures is still unknown, especially for the rapid solidification process. This paper investigated the microstructural evolution of a selective laser melted maraging steel during the rapid solidification process via resistance spot welding. Asymmetrical fusion zone with boat shape was found in the spot weld due to the rougher surface and larger electrical resistance of maraging steel via selective laser melting process. The rapid expansion of fusion zone at end of welding process was caused by the carbide formation at the heat-affected zone of maraging steel via selective laser melting process. Besides, printing orientation affected the surface roughness of a selective laser melted maraging steel and subsequently significantly influence the early stage of formation of fusion zone of additively manufactured maraging steel. We expect that our findings will pave the way to the future application of additively manufactured steels in the industries.

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 Fabrication of Mesh Patterns Using a Selective Laser-Melting Process

2019 ◽  
Vol 9 (9) ◽  
pp. 1922 ◽  
Author(s):  
Tae Woo Hwang ◽  
Young Yun Woo ◽  
Sang Wook Han ◽  
Young Hoon Moon
Keyword(s):  
Selective Laser Melting ◽  
Laser Scanning ◽  
Dimensional Accuracy ◽  
Base Plate ◽  
Steel Powder ◽  
Melting Process ◽  
304 Stainless Steel ◽  
Process Conditions ◽  
Laser Melting ◽  
Metal Mesh

The selective laser-melting (SLM) process can be applied to the additive building of complex metal parts using melting metal powder with laser scanning. A metal mesh is a common type of metal screen consisting of parallel rows and intersecting columns. It is widely used in the agricultural, industrial, transportation, and machine protection sectors. This study investigated the fabrication of parts containing a mesh pattern from the SLM of AISI 304 stainless steel powder. The formation of a mesh pattern has a strong potential to increase the functionality and cost-effectiveness of the SLM process. To fabricate a single-layered thin mesh pattern, laser layering has been conducted on a copper base plate. The high thermal conductivity of copper allows heat to pass through it quickly, and prevents the adhesion of a thin laser-melted layer. The effects of the process conditions such as the laser scan speed and scanning path on the size and dimensional accuracy of the fabricated mesh patterns were characterized. As the analysis results indicate, a part with a mesh pattern was successfully obtained, and the application of the proposed method was shown to be feasible with a high degree of reliability.

scholarly journals Selective Laser Melting Process of Al–Based Pyramidal Horns for the W-Band: Fabrication and Testing

2021 ◽  
Author(s):  
L. Lamagna ◽  
A. Paiella ◽  
S. Masi ◽  
L. Bottini ◽  
A. Boschetto ◽  
...  
Keyword(s):  
Selective Laser Melting ◽  
High Surface ◽  
Melting Process ◽  
Horn Antenna ◽  
Post Processing ◽  
Laser Melting ◽  
Performance Impact ◽  
Horn Antennas ◽  
Sand Blasting ◽  
W Band

AbstractIn the context of exploring the possibility of using Al-powder Selective Laser Melting to fabricate horn antennas for astronomical applications at millimeter wavelengths, we describe the design, the fabrication, the mechanical characterization, and the electromagnetic performance of additive manufactured horn antennas for the W-band. Our aim, in particular, is to evaluate the performance impact of two basic kinds of surface post-processing (manual grinding and sand-blasting) to deal with the well-known issue of high surface roughness in 3D printed devices. We performed comparative tests of co-polar and cross-polar angular response across the whole W-band, assuming a commercially available rectangular horn antenna as a reference. Based on gain and directivity measurements of the manufactured samples, we find decibel-level detectable deviations from the behavior of the reference horn antenna, and marginal evidence of performance degradation at the top edge of the W-band. We conclude that both kinds of post-processing allow achieving good performance for the W-band, but the higher reliability and uniformity of the sand-blasting post-process encourage exploring similar techniques for further development of aluminum devices at these frequencies.

Fabrication and mechanical properties of Al–Si-based alloys by selective laser melting process

2021 ◽  
pp. 1-8
Author(s):  
Yeong Seong Eom ◽  
Kyung Tae Kim ◽  
Dong Won Kim ◽  
Soo ho Jung ◽  
Jung Woo Nam ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Selective Laser Melting ◽  
Melting Process ◽  
Laser Melting ◽  
Selective Laser Melting Process

A study on the effect of energy input on spatter particles creation during selective laser melting process

2018 ◽  
Vol 20 ◽  
pp. 33-43 ◽  
Author(s):  
Mohsen Taheri Andani ◽  
Reza Dehghani ◽  
Mohammad Reza Karamooz-Ravari ◽  
Reza Mirzaeifar ◽  
Jun Ni
Keyword(s):  
Selective Laser Melting ◽  
Energy Input ◽  
Melting Process ◽  
Laser Melting ◽  
Selective Laser Melting Process
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