Optimization of Thin Walls With Sharp Corners in SS316L and IN718 Alloys Manufactured with Laser Metal Deposition

In this work, the manufacture of thin walls with sharp corners has been optimized by adjusting the limits of a 3-axis cartesian kinematics through data recorded and analyzed off-line, such as axis speed, acceleration and the positioning of the X and Y axes. The study was carried out with two powder materials (SS316L and IN718) using the directed energy deposition process with laser. 1 mm thick walls were obtained with only one bead per layer and straight/sharp corners at 90º. After adjusting the in-position parameter G502 for positioning precision on the FAGOR 8070 CNC system, it has been possible to obtain walls with minimal accumulation of material in the corner, and with practically constant layer thickness and height, with a radii of internal curvature between 0.11 and 0.24 mm for two different precision configuration. The best results have been obtained by identifying the correct balance between the decrease in programmed speed and the precision in the positioning to reach the point defined as wall corner, with speed reductions of 29% for a programmed speed of 20 mm/s and 61% for a speed of 40 mm/s. The walls show minimal defects such as residual porosities, and the microstructure is adequate.

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Optimization of Thin Walls with Sharp Corners in SS316L and IN718 Alloys Manufactured with Laser Metal Deposition

Journal of Manufacturing and Materials Processing ◽

10.3390/jmmp5010005 ◽

2021 ◽

Vol 5 (1) ◽

pp. 5

Author(s):

Juan Carlos Pereira ◽

Herman Borovkov ◽

Fidel Zubiri ◽

Mari Carmen Guerra ◽

Josu Caminos

Keyword(s):

Layer Thickness ◽

Energy Deposition ◽

Deposition Process ◽

Metal Deposition ◽

Powder Materials ◽

Laser Metal Deposition ◽

Thin Walls ◽

Directed Energy ◽

Position Parameter ◽

Sharp Corners

In this work, the manufacture of thin walls with sharp corners has been optimized by adjusting the limits of a 3-axis cartesian kinematics through data recorded and analyzed off-line, such as axis speed, acceleration and the positioning of the X and Y axes. The study was carried out with two powder materials (SS316L and IN718) using the directed energy deposition process with laser. Thin walls were obtained with 1 mm thickness and only one bead per layer and straight/sharp corners at 90°. After adjusting the in-position parameter G502 for positioning precision on the FAGOR 8070 CNC system, it has been possible to obtain walls with minimal accumulation of material in the corner, and with practically constant layer thickness and height, with a radii of internal curvature between 0.11 and 0.24 mm for two different precision configuration. The best results have been obtained by identifying the correct balance between the decrease in programmed speed and the precision in the positioning to reach the point defined as wall corner, with speed reductions of 29% for a programmed speed of 20 mm/s and 61% for a speed of 40 mm/s. The walls show minimal defects such as residual porosities, and the microstructure is adequate.

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Laser Metal Deposition Process

3D Printing ◽

10.4018/978-1-5225-1677-4.ch009 ◽

2017 ◽

pp. 172-182 ◽

Cited By ~ 1

Author(s):

Rasheedat M. Mahamood

Keyword(s):

Additive Manufacturing ◽

Manufacturing Process ◽

Computer Aided Design ◽

Experimental Studies ◽

Deposition Process ◽

Metal Deposition ◽

Functionally Graded ◽

Laser Metal Deposition ◽

Graded Material ◽

Directed Energy

Laser metal deposition process belongs to the directed energy deposition class of additive manufacturing process that is capable of producing highly complex part directly from the three dimensional (3D) computer aided design file of the component by adding materials layer after layers. Laser metal deposition process is a very important additive manufacturing process and it is the only class of additive manufacturing process that can be used to repair valued component parts which were not repairable in the past. Also because this additive manufacturing process can handle multiple materials simultaneously, it is used to produce part with functionally graded material. Some of the features of the laser metal deposition process are described in this chapter. Some experimental studies on the laser metal deposition of Titanium alloy- composite are also presented.

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