Investigating the Sensitivity of Particle Size Distribution on Part Geometry in Additive Manufacturing

2020 ◽  
Author(s):  
Vaishak Ramesh Sagar ◽  
Samuel Lorin ◽  
Johan Göhl ◽  
Johannes Quist ◽  
Christoffer Cromvik ◽  
...  
Keyword(s):  
Particle Size ◽  
Additive Manufacturing ◽  
Particle Size Distribution ◽  
Size Distribution ◽  
Complex Geometry ◽  
Structural Mechanics ◽  
Raw Material ◽  
Test Bed ◽  
Powder Bed ◽  
Melted Zone

Abstract Selective laser melting process is a powder bed fusion additive manufacturing process that finds applications in aerospace and medical industries for its ability to produce complex geometry parts. As the raw material used is in powder form, particle size distribution (PSD) is a significant characteristic that influences the build quality in turn affecting the functionality and aesthetics aspects of the end product. This paper investigates the effect of PSD on deformation for 316L stainless steel powder, where three coupled in-house simulation tools based on Discrete Element Method (DEM), Computational Fluid Dynamics (CFD), and Structural Mechanics are employed. DEM is used for simulating the powder distribution based on the different particle size distribution of the powder. The CFD is used as a virtual test bed to determine thermal parameters such as density, heat capacity and thermal conductivity of the powder bed viewed as a continuum. The values found as a stochastic function of the powder distribution is used to test the sensitivity of the melted zone and distortion using Structural Mechanics. Results showed significant influence of particle size distribution on the packing density, surface height, surface roughness, the stress state and displacement of the melted zone. The results will serve as a catalyst in developing geometry assurance strategies to minimize the effect of particle size distribution on the geometric quality of the printed part.

scholarly journals Plasma Spheroidisation of Irregular Ti6Al4V Powder for Powder Bed Fusion

Metals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1763
Author(s):  
Nthateng Nkhasi ◽  
Willie du Preez ◽  
Hertzog Bissett
Keyword(s):  
Particle Size ◽  
Additive Manufacturing ◽  
Particle Size Distribution ◽  
Size Distribution ◽  
Metal Powder ◽  
Weight Ratio ◽  
High Strength ◽  
Powder Bed Fusion ◽  
Metal Powders ◽  
Powder Bed

Metal powders suitable for use in powder bed additive manufacturing processes should ideally be spherical, dense, chemically pure and of a specified particle size distribution. Ti6Al4V is commonly used in the aerospace, medical and automotive industries due to its high strength-to-weight ratio and excellent corrosion resistance properties. Interstitial impurities in titanium alloys have an impact upon mechanical properties, particularly oxygen, nitrogen, hydrogen and carbon. The plasma spheroidisation process can be used to spheroidise metal powder consisting of irregularly shaped particles. In this study, the plasma spheroidisation of metal powder was performed on Ti6Al4V powder consisting of irregularly shaped particles. The properties of the powder relevant for powder bed fusion that were determined included the particle size distribution, morphology, particle porosity and chemical composition. Conclusions were drawn regarding the viability of using this process to produce powder suitable for additive manufacturing.

scholarly journals Effect of Particle Size Distribution on Laser Powder Bed Fusion Manufacturability of Copper

2021 ◽  
Author(s):  
Massimiliano Bonesso ◽  
Pietro Rebesan ◽  
Claudio Gennari ◽  
Simone Mancin ◽  
Razvan Dima ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Particle Size ◽  
Particle Size Distribution ◽  
Size Distribution ◽  
Physical And Mechanical Properties ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Cooling Channels ◽  
Scan Speed

AbstractOne of the major benefits of the Laser Powder Bed Fusion (LPBF) technology is the possibility of fabrication of complex geometries and features in only one-step of production. In the case of heat exchangers in particular, this is very convenient for the fabrication of conformal cooling channels which can improve the performance of the heat transfer capability. Yet, obtaining dense copper parts printed via LPBF presents two major problems: the high reflectivity of 1 μm (the wavelength of commonly used laser sources) and the high thermal conductivity of copper that limits the maximum local temperature that can be attained. This leads to the formation of porous parts.In this contribution, the influence of the particle size distribution of the powder on the physical and mechanical properties of parts produced via LPBF is studied. Three copper powders lots with different particle size distributions are used in this study. The effect on densification from two laser scan parameters (scan speed and hatching distance) and the influence of contours scans on the lateral surface roughness is reported. Subsequently, samples manufactured with the optimal process parameters are tested for thermal and mechanical properties evaluation.

A SIMULATION STUDY ON THE EFFECT OF PARTICLE SIZE DISTRIBUTION ON THE PRINTED GEOMETRY IN SELECTIVE LASER MELTING

2021 ◽  
pp. 1-14
Author(s):  
Vaishak Ramesh Sagar ◽  
Samuel Lorin ◽  
Johan Göhl ◽  
Johannes Quist ◽  
Christoffer Cromvik ◽  
...  
Keyword(s):  
Particle Size ◽  
Particle Size Distribution ◽  
Size Distribution ◽  
Layer Thickness ◽  
Selective Laser Melting ◽  
Laser Melting ◽  
Powder Bed ◽  
Mean Particle Size ◽  
Final Layer ◽  
Effect Of Particle Size

Abstract Selective laser melting (SLM) process is a powder bed fusion additive manufacturing process that finds applications in aerospace and medical industries for its ability to produce complex geometry parts. As the raw material used is in powder form, particle size distribution (PSD) is a significant characteristic that influences the build quality in turn affecting the functionality and aesthetics aspects of the product. This paper investigates the effect of PSD on the printed geometry for 316L stainless steel powder, where three coupled in-house simulation tools based on Discrete Element Method (DEM), Computational Fluid Dynamics (CFD), and Structural Mechanics are employed. DEM is used for simulating the powder bed distribution based on the different powder PSD. The CFD is used as a virtual testbed to determine thermal parameters such as heat capacity and thermal conductivity of the powder bed viewed as a continuum. The values found as a stochastic function of the powder distribution is used to analyse the effect on the melted zone and deformation using Structural Mechanics. Results showed that mean particle size and PSD had a significant effect on the packing density, melt pool layer thickness, and the final layer thickness after deformation. Specifically, a narrow particle size distribution with smaller mean particle size and standard deviation produced solidified final layer thickness closest to nominal layer thickness. The proposed simulation approach and the results will catalyze in development of geometry assurance strategies to minimize the effect of particle size distribution on the geometric quality of the printed part.

Additive Manufacturing of Nickel-Based Super Alloys for Aero Engine Applications

2020 ◽  
pp. 48-70
Author(s):  
Raja A. ◽  
Mythreyi O. V. ◽  
Jayaganthan R.
Keyword(s):  
Additive Manufacturing ◽  
Complex Geometry ◽  
Source Parameters ◽  
Raw Material ◽  
Layer By Layer ◽  
Powder Bed ◽  
Complex Design ◽  
Direct Energy ◽  
Second Phases ◽  
Metal Addition

Ni based super alloys are widely used in engine turbines because of their proven performance at high temperatures. Manufacturing these parts by additive manufacturing (AM) methods provides researchers a lot of creative space for complex design to improve efficiency. Powder bed fusion (PBF) and direct energy deposition (DED) are the two most widely-used metal AM methods. Both methods are influenced by the source, parameters, design, and raw material. Selective laser melting is one of the laser-based PBF techniques to create small layer thickness and complex geometry with greater accuracy and properties. The layer-by-layer metal addition generates epitaxial growth and solidification in the built direction. There are different second phases in the Ni-based superalloys. This chapter details the micro-segregation of these particles and its influence on the microstructure, and mechanical properties are dependent on the process influencing parameters, the thermal kinetics during the process, and the post-processing treatments.

Concentration of TiOSO4 on Rutile White via Short Sulfate Process

2014 ◽  
Vol 968 ◽  
pp. 40-43 ◽  
Author(s):  
Cong Xue Tian
Keyword(s):  
Particle Size ◽  
Particle Size Distribution ◽  
Size Distribution ◽  
Raw Material ◽  
Thermal Hydrolysis ◽  
High Quality ◽  
White Pigment ◽  
Hydrolysis Process ◽  
Sulfate Process ◽  
Favorable Structure

Short sulfate process was developed to produce rutile TiO2 white pigment by using low concentration industrial TiOSO4 solution as raw material via self-generated seeded thermal hydrolysis route. The concentration of TiOSO4 solution had significantly influenced the structure and pigment properties of rutile TiO2 white pigment. The samples were characterized by XRD, particle size distribution and pigment properties test. Appropriate concentration of TiOSO4 was beneficial to promoting hydrolysis process in a proper way and obtaining favorable structure and high quality white pigment. The optimized concentration of TiOSO4 solution was of 191.20 g/L.

Combustion Synthesis of β-SiAlON Using 3D Ball Milling

2017 ◽  
Vol 898 ◽  
pp. 1717-1723 ◽  
Author(s):  
Xue Mei Yi ◽  
Shota Suzuki ◽  
Xiong Zhang Liu ◽  
Ran Guo ◽  
Tomohiro Akiyama
Keyword(s):  
Particle Size ◽  
Particle Size Distribution ◽  
Size Distribution ◽  
Combustion Synthesis ◽  
Ball Mill ◽  
Raw Materials ◽  
Raw Material ◽  
Size Distributions ◽  
Particle Size Distributions ◽  
Material Particle

Combustion synthesis (CS) of β-SiAlON was conducted using a 3D ball mill, with a focus on the effect of the 2D/3D ball mill premixing conditions on the CS raw material particle size as well as on the yield and grain shape of the final products. The results showed that the particle size distribution of the raw materials was significantly affected by the premixing conditions. Various particle sizes and particle size distributions could easily be obtained by using a 3D mill instead of a 2D mill due to the complex biaxial rotation movement of 3D milling. The particle size was more sensitive to the rotation ratio (vertical spin/horizontal spin, Vv/Vh) than the rotation rate when using 3D milling. Finally, β-SiAlON with less than 5 mass% unreacted Si was obtained using premix milling conditions of 135×200 [vertical spin (rpm) × horizontal spin (rpm)]. The grain shapes of the final products were clearly influenced by the particle size distribution of the raw mixtures.

scholarly journals The Study of Particle Size Distribution of Micronized Oat Bran Layer

2020 ◽  
Vol 24 (2) ◽  
pp. 45-54
Author(s):  
Dariusz Dziki ◽  
Wojciech Tarasiuk ◽  
Grzegorz Łysiak ◽  
Paweł Jochymek
Keyword(s):  
Particle Size ◽  
Particle Size Distribution ◽  
Size Distribution ◽  
Laser Light ◽  
Rotation Speed ◽  
Raw Material ◽  
Coarse Particles ◽  
Oat Bran ◽  
Size Of Particles ◽  
Sense Of Touch

AbstractThe aim of this work was to study the particle size distribution of micronized oat bran. An impact classified mill was used to pulverizing. Before the pulverizing raw material was sterilized using overheated steam at 150°C during 3.5 min. The moisture of bran after sterilization decreased from 7.2 to about 3.9%. Five speeds of the rotor disc were used: 2600, 2970, 3340, and 3710 rpm. For each speed of the rotor disc the following speeds of classifier wheel were applied: 480, 965, 1450, 1930, 2410 and 2890 rpm. The particle size distribution of oat bran layer was measured by laser light scattering. Moreover, the sense of touch of coarse particles of micronized oat bran on a tongue was assessed according to five point scale. The largest fragmentation of the oat bran was obtained at a disc speed of 3710 rpm and at a classifier rotation speed of 1930 rpm, whereas the most coarse particles were obtained when these parameters were 3340 rpm and 480 rpm, respectively. On the other hand, the highest uniformity in size of particles in size was observed when the lowest speed of disc and classifier were used. Moreover, for the most samples the pulverized particles of oat bran were almost not discernible on tongue.

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