Selective Laser Melting of the Inconel 718 Nickel Superalloy

The results of the research on selective laser melting process of the Inconel 718 superalloy powder under conditions of additive manufacturing of parts for special purposes are presented. The influence of process parameters on the quality of manufactured parts is shown. Process parameters which allow manufacturing parts with the density close to 100%, are determined. Also, the results of mechanical tests and investigation of microstructure are presented.

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The Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al6061 and AlSi10Mg Alloys

Materials ◽

10.3390/ma12010012 ◽

2018 ◽

Vol 12 (1) ◽

pp. 12 ◽

Cited By ~ 26

Author(s):

Ahmed Maamoun ◽

Yi Xue ◽

Mohamed Elbestawi ◽

Stephen Veldhuis

Keyword(s):

Mechanical Properties ◽

Selective Laser Melting ◽

Process Parameters ◽

High Strength ◽

Melting Process ◽

Laser Melting ◽

Influence Of Process Parameters ◽

Wide Range ◽

Powder Characteristics

Additive manufacturing (AM) offers customization of the microstructures and mechanical properties of fabricated components according to the material selected and process parameters applied. Selective laser melting (SLM) is a commonly-used technique for processing high strength aluminum alloys. The selection of SLM process parameters could control the microstructure of parts and their mechanical properties. However, the process parameters limit and defects obtained inside the as-built parts present obstacles to customized part production. This study investigates the influence of SLM process parameters on the quality of as-built Al6061 and AlSi10Mg parts according to the mutual connection between the microstructure characteristics and mechanical properties. The microstructure of both materials was characterized for different parts processed over a wide range of SLM process parameters. The optimized SLM parameters were investigated to eliminate internal microstructure defects. The behavior of the mechanical properties of parts was presented through regression models generated from the design of experiment (DOE) analysis for the results of hardness, ultimate tensile strength, and yield strength. A comparison between the results obtained and those reported in the literature is presented to illustrate the influence of process parameters, build environment, and powder characteristics on the quality of parts produced. The results obtained from this study could help to customize the part’s quality by satisfying their design requirements in addition to reducing as-built defects which, in turn, would reduce the amount of the post-processing needed.

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On the Effect of Selective Laser Melting Process Parameters on the Microstructure and Mechanical Properties of Al Alloys

10.20944/preprints201812.0104.v1 ◽

2018 ◽

Author(s):

Ahmed Maamoun ◽

Yi Xue ◽

Mohamed Elbestawi ◽

Stephen Veldhuis

Keyword(s):

Mechanical Properties ◽

Selective Laser Melting ◽

Process Parameters ◽

High Strength ◽

Melting Process ◽

Laser Melting ◽

Influence Of Process Parameters ◽

Microstructure And Mechanical Properties ◽

Wide Range

Additive manufacturing (AM) offers customization of microstructure and mechanical properties of fabricated components according to the material selected, and process parameters applied. Selective laser melting (SLM) is the commonly used technique for processing high strength aluminum alloys. Selection of SLM process parameters could control the microstructure of parts and their mechanical properties. However, the process parameters limit and defects obtained inside the as-built parts present obstacles to customized part production. This study investigates the influence of SLM process parameters on the quality of as-built Al6061 and AlSi10Mg parts according to the mutual connection between the microstructure characteristics and mechanical properties. The microstructure of both materials was characterized for different parts processed over a wide range of SLM process parameters. The optimized SLM parameters were investigated to eliminate the internal microstructure defects. The behaviour of mechanical properties of parts was presented through regression models generated from the design of experiment (DOE) analysis for the results of hardness, ultimate tensile strength, and yield strength. A comparison between the results obtained and that reported in the literature is presented to illustrate the influence of process parameters, build environment, and powder characteristics on the quality of parts produced. The results obtained from this study could help to customize the part’s quality by satisfying their design requirements in addition to reducing the as-built defects which in turn reduce the amount of the post-processing needed.

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The Influence of Process Parameters and Scanning Strategy on Lower Surface Quality of TA15 Parts Fabricated by Selective Laser Melting

Metals ◽

10.3390/met10091228 ◽

2020 ◽

Vol 10 (9) ◽

pp. 1228

Author(s):

Junjie Jiang ◽

Jianming Chen ◽

Zhihao Ren ◽

Zhongfa Mao ◽

Xiangyu Ma ◽

...

Keyword(s):

Surface Quality ◽

Selective Laser Melting ◽

Process Parameters ◽

Flexible Manufacturing ◽

Molten Pool ◽

Lower Surface ◽

Laser Melting ◽

Scanning Strategy ◽

Influence Of Process Parameters

With superior flexible manufacturing capability, selective laser melting (SLM) has attracted more and more attention in the aerospace, medical, and automotive industries. However, the poor quality of the lower surface in overhanging structures is still one of the factors that limits the wide application of SLM. In this work, the influence of process parameters and scanning strategy on the lower surface quality of SLMed TA15 (Ti-6Al-2Zr-1Mo-1V) titanium alloy parts were studied. The results showed that the laser surface energy density (EF) had a significant influence on the quality of the lower surface. Excessive EF led to obvious sinking of the molten pool and a serious slag hanging phenomenon. However, the too low EF easily contributed to the insufficient powder fusion in the lower surface area, which led to the agglomeration of a molten pool during core processing, resulting in slag hanging, pores, and powder spalling that reduced the quality of the lower surface. Moreover, the cross-remelting strategy and non-remelting strategy gained better surface quality at the low EF and high EF, respectively. In addition, it was found that the quality of the lower surface could be quickly and accurately evaluated by the cooling time of the molten pool during the processing of the lower surface. This research can increase the understanding of the forming mechanism of the lower surface and has certain guiding significance for the process optimization of the lower surface.

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Influence of process parameters on surface quality of CoCrMo produced by selective laser melting

The International Journal of Advanced Manufacturing Technology ◽

10.1007/s00170-015-7040-3 ◽

2015 ◽

Vol 80 (5-8) ◽

pp. 985-995 ◽

Cited By ~ 36

Author(s):

Yurivania Pupo ◽

Karla P. Monroy ◽

Joaquim Ciurana

Keyword(s):

Surface Quality ◽

Selective Laser Melting ◽

Process Parameters ◽

Laser Melting ◽

Influence Of Process Parameters

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Effect of Selective Laser Melting Process Parameters on the Quality of Al Alloy Parts: Powder Characterization, Density, Surface Roughness, and Dimensional Accuracy

Materials ◽

10.3390/ma11122343 ◽

2018 ◽

Vol 11 (12) ◽

pp. 2343 ◽

Cited By ~ 43

Author(s):

Ahmed Maamoun ◽

Yi Xue ◽

Mohamed Elbestawi ◽

Stephen Veldhuis

Keyword(s):

Surface Roughness ◽

Selective Laser Melting ◽

Process Parameters ◽

Dimensional Accuracy ◽

High Strength ◽

Melting Process ◽

Al Alloys ◽

Al Alloy ◽

Laser Melting

Additive manufacturing (AM) of high-strength Al alloys promises to enhance the performance of critical components related to various aerospace and automotive applications. The key advantage of AM is its ability to generate lightweight, robust, and complex shapes. However, the characteristics of the as-built parts may represent an obstacle to the satisfaction of the parts’ quality requirements. The current study investigates the influence of selective laser melting (SLM) process parameters on the quality of parts fabricated from different Al alloys. A design of experiment (DOE) was used to analyze relative density, porosity, surface roughness, and dimensional accuracy according to the interaction effect between the SLM process parameters. The results show a range of energy densities and SLM process parameters for AlSi10Mg and Al6061 alloys needed to achieve “optimum” values for each performance characteristic. A process map was developed for each material by combining the optimized range of SLM process parameters for each characteristic to ensure good quality of the as-built parts. This study is also aimed at reducing the amount of post-processing needed according to the optimal processing window detected.

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