scholarly journals Improved Process Efficiency in Laser-Based Powder Bed Fusion of Nanoparticle Coated Maraging Tool Steel Powder

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3465
Author(s):  
Oliver Pannitz ◽  
Felix Großwendt ◽  
Arne Lüddecke ◽  
Arno Kwade ◽  
Arne Röttger ◽  
...  
Keyword(s):  
Tool Steel ◽  
Steel Powder ◽  
Process Efficiency ◽  
Powder Materials ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
Laser Systems ◽  
Additional Improvement ◽  
Few Layer Graphene ◽  
The Impact

Research and development in the field of metal-based additive manufacturing are advancing steadily every year. In order to increase the efficiency of powder bed fusion of metals using a laser beam system (PBF LB/M), machine manufacturers have implemented extensive optimizations with regard to the laser systems and build volumes. However, the optimization of metallic powder materials using nanoparticle additives enables an additional improvement of the laser–material interaction. In this work, tool steel 1.2709 powder was coated with silicon carbide (SiC), few-layer graphene (FLG), and iron oxide black (IOB) on a nanometer scale. Subsequently, the feedstock material and the modified powder materials were analyzed concerning the reflectance of the laser radiation and processed by PBF-LB/M in a systematic and consistent procedure to evaluate the impact of the nano-additivation on the process efficiency and mechanical properties. As a result, an increased build rate is achieved, exhibiting a relative density of 99.9% for FLG/1.2709 due to a decreased reflectance of this modified powder material. Furthermore, FLG/1.2709 provides hardness values after precipitation hardening with only aging comparable to the original 1.2709 material and is higher than the SiC- and IOB-coated material. Additionally, the IOB coating tends to promote oxide-formation and lack-of-fusion defects.

scholarly journals Application of Laser-Based Powder Bed Fusion for Direct Metal Tooling

Metals ◽  
2021 ◽  
Vol 11 (3) ◽  
pp. 458
Author(s):  
Nader Asnafi
Keyword(s):  
Injection Molding ◽  
Manufacturing Systems ◽  
Lattice Structure ◽  
Steel Powder ◽  
Hot Working ◽  
Powder Materials ◽  
Powder Bed Fusion ◽  
Efficient Design ◽  
Productivity Improvement ◽  
Powder Bed

The journey of production tools in cold working, hot working, and injection molding from rapid tooling to additive manufacturing (AM) by laser-based powder bed fusion (L-PBF) is described. The current machines and their configurations, tool steel powder materials and their properties, and the L-PBF process parameters for these materials are specified. Examples of production tools designed for and made by L-PBF are described. Efficient design, i.e., high tooling efficiency and performance in operation, should be the primary target in tool design. Topology and lattice structure optimization provide additional benefits. Using efficient design, L-PBF exhibits the greatest potential for tooling in hot working and injection molding. L-PBF yields high tooling costs, but competitive total costs in hot working and injection molding. Larger object sizes that can be made by L-PBF, a larger number of powder metals that are designed for different tooling applications, lower feedstock and L-PBF processing costs, further L-PBF productivity improvement, improved surface roughness through L-PBF, and secured quality are some of the targets for the research and development in the future. A system view, e.g., plants with a high degree of automation and eventually with cyber-physically controlled smart L-PBF inclusive manufacturing systems, is also of great significance.

scholarly journals Influence of Different Alloying Strategies on the Mechanical Behavior of Tool Steel Produced by Laser-Powder Bed Fusion

Materials ◽  
2021 ◽  
Vol 14 (12) ◽  
pp. 3344
Author(s):  
Abootorab Baqerzadeh Chehreh ◽  
Anna Strauch ◽  
Felix Großwendt ◽  
Arne Röttger ◽  
Rainer Fechte-Heinen ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Tool Steel ◽  
Defect Density ◽  
Steel Powder ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Static Mechanical ◽  
Particle Parameters

Additive manufacturing is a high-potential technique that allows the production of components with almost no limitation in complexity. However, one of the main factors that still limits the laser-based additive manufacturing is a lack of processable alloys such as carbon martensitic hardenable tool steels, which are rarely investigated due to their susceptibility to cold cracking. Therefore, this study aimed to expand the variety of steels for laser powder bed fusion (L-PBF) by investigating an alternative alloying strategy for hot work tool steel powder. In this study, a comprehensive investigation was performed on the powder and L-PBF processed specimen properties and their correlation with the existing defects. Cubical specimens were created using the following two alloying strategies by means of L-PBF: conventional pre-alloyed gas-atomized powder and a mixture of gas-atomized powder with mechanically crushed pure elements and ferroalloys. The influence of the particle parameters such as morphology were correlated to the defect density and resulting quasi-static mechanical properties. Micromechanical behavior and damage evolution of the processed specimens were investigated using in situ computed tomography. It was shown that the properties of the L-PBF processed specimens obtained from the powder mixture performs equal or better compared to the specimens produced from conventional powder.

Improvement of Build Speed and Quality of H13 Tool Steel Processed by Laser-Beam Powder Bed Fusion with a High-Power Laser

2021 ◽  
Vol 68 (10) ◽  
pp. 415-421
Author(s):  
Takashi MIZOGUCHI ◽  
Takaya NAGAHAMA ◽  
Makoto TANO ◽  
Shigeru MATSUNAGA ◽  
Takayuki YOSHIMI ◽  
...  
Keyword(s):  
Laser Beam ◽  
Tool Steel ◽  
High Power ◽  
Powder Bed Fusion ◽  
High Power Laser ◽  
Power Laser ◽  
Powder Bed ◽  
H13 Tool Steel

scholarly journals Bonding Integrity of Hybrid 18Ni300-17-4 PH Steel Using The Laser Powder Bed Fusion Process For The Fabrication of Plastic Injection Mould Inserts

2021 ◽  
Author(s):  
Yuk Lun Simon Chan ◽  
Olaf Diegel ◽  
Xun Xu
Keyword(s):  
Tool Steel ◽  
High Performance ◽  
High Volume ◽  
Successful Outcome ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Injection Mould ◽  
Powder Bed ◽  
Plastic Injection Mould ◽  
Plastic Injection

Abstract Laser powder bed fusion (LPBF) is a metal additive manufacturing (AM) process for fabricating high-performance functional parts and tools in various metallic alloys, such as titanium, aluminium and tool steels. The process can produce geometrically complex features such as conformal cooling channels (CCC) in plastic injection mould inserts to improve cooling efficiency. A recent attempt using a hybrid-build LPBF AM technique to fabricate aluminium mould inserts with CCC attained a substantial reduction in processing time, making it an attractive alternative method to the mould-making industry. Also, the successful bonding of aluminium powder with wrought aluminium alloys proved the practicability of this concept. This study further investigates whether a similarly successful outcome could apply to tool steel since tool steel is the preferred material for constructing high-grade high-volume plastic injection moulds. In this investigation, hybrid 18Ni300 powder-wrought 17-4 PH steel parts were additively fabricated using the hybrid-build LPBF technique, followed by various post-build heat treatments. The mechanical and metallurgical properties of the samples’ bonded interface were examined. Microstructure analysis revealed homogenous powder-substrate fusion across the interface region. Results from tensile tests confirmed strong powder-substrate bonding as none of the tensile fractures occurred at the interface. A direct post-build one-hour age-hardening treatment achieved the best combination of hardness, tensile strength, and ductility. The overall result demonstrates that hybrid-built 18Ni300-17-4 PH steel can be a material choice for manufacturing durable and high-performance injection mould inserts for high-volume production.

In-Situ Monitoring of Laser Powder Bed Fusion Process Anomalies via a Comprehensive Analysis of Off-Axis Camera Data

2020 ◽  
Author(s):  
Chaitanya Krishna Prasad Vallabh ◽  
Yubo Xiong ◽  
Xiayun Zhao
Keyword(s):  
Real Time ◽  
Network Architecture ◽  
Video Data ◽  
In Situ Monitoring ◽  
Process Efficiency ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Monitoring Method ◽  
Powder Bed

Abstract In-situ monitoring of a Laser Powder-Bed Fusion (LPBF) additive manufacturing process is crucial in enhancing the process efficiency and ensuring the built part integrity. In this work, we present an in-situ monitoring method using an off-axis camera for monitoring layer-wise process anomalies. The in-situ monitoring is performed with a spatial resolution of 512 × 512 pixels, with each pixel representing 250 × 250 μm and a relatively high data acquisition rate of 500 Hz. An experimental study is conducted by using the developed in-situ off-axis method for monitoring the build process for a standard tensile bar. Real-time video data is acquired for each printed layer. Data analytics methods are developed to identify layer-wise anomalies, observe powder bed characteristics, reconstruct 3D part structure, and track the spatter dynamics. A deep neural network architecture is trained using the acquired layer-wise images and tested by images embedded with artificial anomalies. The real-time video data is also used to perform a preliminary spatter analysis along the laser scan path. The developed methodology is aimed to extract as much information as possible from a single set of camera video data. It will provide the AM community with an efficient and capable process monitoring tool for process control and quality assurance while using LPBF to produce high-standard components in industrial (such as, aerospace and biomedical industries) applications.

scholarly journals Evaluation of post-treatments of novel hot-work tool steel manufactured by laser powder bed fusion for aluminum die casting applications

2021 ◽  
Vol 800 ◽  
pp. 140305
Author(s):  
A.M. Vilardell ◽  
S.B. Hosseini ◽  
M. Åsberg ◽  
A. Dahl-Jendelin ◽  
P. Krakhmalev ◽  
...  
Keyword(s):  
Tool Steel ◽  
Die Casting ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Hot Work Tool Steel

Microstructure of Built Part Obtained by Powder Bed Fusion Process with Metal

2019 ◽  
Vol 825 ◽  
pp. 1-6
Author(s):  
Tatsuaki Furumoto ◽  
Kyota Egashira ◽  
Souta Matsuura ◽  
Makoto Nikawa ◽  
Masato Okada ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Metal Powder ◽  
Maraging Steel ◽  
Process Parameters ◽  
Steel Powder ◽  
Powder Bed Fusion ◽  
Laser Melting ◽  
Powder Bed ◽  
Suitable Heat Treatment ◽  
Deposited Metal

The influence of various process parameters on the building of maraging steel powder by the selective laser melting (SLM) processes is investigated. The microstructure in the built part was observed and the influence of the heat treatment was evaluated. As results, the depth of solidified layer was higher than that of deposited metal powder, and its value was influenced with the process parameters. The microstructure in the boundary between the built part and the substrate was quite different from the built part even if the suitable heat treatment was performed.

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