Research on the Design of the Laser Beam in SLS Rapid Prototyping Machine

2019 ◽  
Vol 894 ◽  
pp. 140-148
Author(s):  
Vo Tuyen ◽  
Thanh Nam Nguyen ◽  
Khanh Dien Le
Keyword(s):  
Additive Manufacturing ◽  
Laser Beam ◽  
Rapid Prototyping ◽  
Powder Material ◽  
Selective Laser Sintering ◽  
Rapid Prototype ◽  
Powdered Material ◽  
Laser Source ◽  
Technical Parameters ◽  
Technical Requirements

Selective Laser Sintering (SLS) is an HYPERLINK "https://en.wikipedia.org/wiki/Additive_manufacturing" \o "Additive manufacturing" additive manufacturing (AM) technique that uses a HYPERLINK "https://en.wikipedia.org/wiki/Laser" \o "Laser" Laser as the power source to HYPERLINK "https://en.wikipedia.org/wiki/Sintering" \o "Sintering" sinter powdered material, typically HYPERLINK "https://en.wikipedia.org/wiki/Nylon" \o "Nylon" nylon/ HYPERLINK "https://en.wikipedia.org/wiki/Polyamide" \o "Polyamide" polyamide HYPERLINK "https://en.wikipedia.org/wiki/Selective_laser_sintering" \l "cite_note-1" [7], HYPERLINK "https://en.wikipedia.org/wiki/Selective_laser_sintering" \l "cite_note-2" [8]. A Laser beam HYPERLINK "https://en.wikipedia.org/wiki/Automation" \o "Automation" automatically aims at points in space defined by a HYPERLINK "https://en.wikipedia.org/wiki/3D_modeling" \o "3D modeling" 3D model, binding the material together to create a solid structure. In the SLS rapid prototype machine, a high power CO2 Laser sources is applied for sintering the powder material to its melting point temperature. The ability of application of a Laser radiation for sintering the material depends on the power of energy source and the time of interaction of radiation with the material of the product. Otherwise, the design of Laser beam for sintering powder material depends on the technical parameters such as power Laser source, Laser point size, type and focus of lenses.... This article presents a study on the design of our own Laser beam sintering in the SLS rapid prototype that satisfies the technical requirements. The results of testing show that the designed and manufactured Laser beam instrument in SLS rapid prototype machine in our laboratory can be approved because it satisfies all the technological requirements of the medium range of SLS rapid prototyping machine.

Optimization and analysis of porosity and roughness in selective laser melting 316L parts

2018 ◽  
Vol 1 (90) ◽  
pp. 5-15 ◽  
Author(s):  
M. Król ◽  
J. Mazurkiewicz ◽  
S. Żołnierczyk
Keyword(s):  
Stainless Steel ◽  
Additive Manufacturing ◽  
Laser Beam ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
316L Stainless Steel ◽  
Selective Laser Sintering ◽  
Technological Parameters ◽  
Laser Melting ◽  
Research Issues

Purpose: The investigations have been carried out on 316L stainless steel parts fabricated by Selective Laser Melting (SLM) technique. The study aimed to determine the effect of SLM parameters on porosity, hardness, and structure of 316L stainless steel. Design/methodology/approach: The analyses were conducted on 316L stainless steel parts by using AM125 SLM machine by Renishaw. The effects of the different manufacturing process parameters as power output, laser distance between the point’s melted metal powder during additive manufacturing as well as the orientation of the model relative to the laser beam and substrate on porosity, hardness, microstructure and roughness were analysed and optimised. Findings: The surface quality parts using 316L steel with the assumed parameters of the experiment depends on the process parameters used during the SLM technique as well as the orientation of formed walls of the model relative to the substrate and thus the laser beam. The lowest roughness of 316L SLM parts oriented perpendicularly to the substrate was found when 100 W and 20 μm the distance point was utilised. The lowest roughness for part oriented at 60° relatives to the substrate was observed when 125 W and the point distance 50 μm was employed. Practical implications: Stainless steel is one of the most popular materials used for selective laser sintering (SLM) processing to produce nearly fully dense components from 3D CAD models. Reduction of porosity is one of the critical research issues within the additive manufacturing technique SLM, since one of the major cost factors is the post-processing. Originality/value: This manuscript can serve as an aid in understanding the importance of technological parameters on quality and porosity of manufactured AM parts made by SLM technique.

Faster Design of Gas Turbine Parts Using Rapid Prototype Models for Verification of Coolant Flow Characteristics

2013 ◽  
Author(s):  
Andrey Sedlov ◽  
Andreas Bauer ◽  
Alexey Mozharov ◽  
Michael Gritsch ◽  
Valery Kostege
Keyword(s):  
Rapid Prototyping ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Selective Laser Sintering ◽  
Turbine Blades ◽  
Flow Characteristics ◽  
Rapid Prototype ◽  
Coolant Flow ◽  
Design Changes ◽  
Machined Parts

One of the keys to successful time-to-market introduction of a gas turbine blading upgrade package is fast-track development. Cooled turbine blades should match the designed coolant mass flow from the first iteration, otherwise, lengthy and expensive wax or core die rework has to be done. Use of rapid prototyping for cooled components allows verification of their flow characteristics during the design phase and the check/calibration of flow predictions, prior to manufacturing. The present paper discusses features of the rapid prototyping process (selective laser sintering) in their application to plastic models of hot gas path components of modern heavy-duty gas turbines. A tailored sintering process was developed and successfully applied also to film cooled parts. Rapid prototype models were flow tested and then design changes were made to achieve the required levels of cooling air flow. Wax and core dies were produced, taking the design changes into account. Coolant flow characteristics of cast and machined parts were compared with those of rapid prototype models and with the design intent for a wide set of configurations and flow conditions. Comparison demonstrates good agreement in flow characteristics between prototyped and production parts, and thus confirms the applicability and reliability of this approach. Use of rapid prototype models significantly reduced the project duration, eliminated rework cost for casting tooling, and ultimately lead to a higher quality end product.

Study of the process of rapid prototyping with laser beam

2006 ◽  
Author(s):  
V. Kovalenko ◽  
M. Anyakin ◽  
P. Kondrashov ◽  
A. Mukhoid ◽  
A. Stepura ◽  
...  
Keyword(s):  
Laser Beam ◽  
Rapid Prototyping

Establishing Specimen Property to Part Performance Relationships for Laser Beam Powder Bed Fusion Additive Manufacturing

2021 ◽  
pp. 106384
Author(s):  
Arash Soltani-Tehrani ◽  
Rakish Shrestha ◽  
Nam Phan ◽  
Mohsen Seifi ◽  
Nima Shamsaei
Keyword(s):  
Additive Manufacturing ◽  
Laser Beam ◽  
Powder Bed Fusion ◽  
Powder Bed

Evaluation of Parts Produced by a Novel Additive Manufacturing Process

2013 ◽  
Vol 315 ◽  
pp. 63-67 ◽  
Author(s):  
Muhammad Fahad ◽  
Neil Hopkinson
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Manufacturing Process ◽  
High Speed ◽  
Three Dimensional ◽  
Coordinate Measuring Machine ◽  
Layer By Layer ◽  
Nylon 12 ◽  
Measuring Machine ◽  
End Use

Rapid prototyping refers to building three dimensional parts in a tool-less, layer by layer manner using the CAD geometry of the part. Additive Manufacturing (AM) is the name given to the application of rapid prototyping technologies to produce functional, end use items. Since AM is relatively new area of manufacturing processes, various processes are being developed and analyzed for their performance (mainly speed and accuracy). This paper deals with the design of a new benchmark part to analyze the flatness of parts produced on High Speed Sintering (HSS) which is a novel Additive Manufacturing process and is currently being developed at Loughborough University. The designed benchmark part comprised of various features such as cubes, holes, cylinders, spheres and cones on a flat base and the build material used for these parts was nylon 12 powder. Flatness and curvature of the base of these parts were measured using a coordinate measuring machine (CMM) and the results are discussed in relation to the operating parameters of the process.The result show changes in the flatness of part with the depth of part in the bed which is attributed to the thermal gradient within the build envelope during build.

Build Time Analysis of Additive Manufacturing for Next Generation SLS Systems

2020 ◽  
Author(s):  
Michael Machado ◽  
Raul Fangueiro ◽  
Daniel Barros ◽  
Luís Nobre ◽  
João Bessa ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Sintering ◽  
Material Point ◽  
Point Of View ◽  
Efficient Production ◽  
Robust Solution ◽  
Functional Product ◽  
Build Time ◽  
Consistent Solution ◽  
Production Solutions

Abstract With the recent advances in the additive manufacturing (AM) production technologies, AM is becoming more common in today’s industry, nowadays is a normal practice to use this solution either to test a new prototype or to manufacture a functional product. The increase application is mainly due to significant developments in the production solutions of the AM. These recent developments are resulting in an increase search for new and more efficient production solutions. This search is always focused in producing more efficiently, with a greater variety of materials and produce part with better quality and proprieties. From an industrial point of view, one of the types of additive manufacturing that is increasing the percentage of use is the selective laser sintering (SLS) technologies. Although this process was first used in the mid-80’s, it has shown great developments in the recent years. This evolution of the process allowed it to become a solid solution even if it is highly time consuming, especially when compared with other types of addictive manufacturing. From the several aspects that make the SLS a robust solution is the fact that it offers a consistent solution to produce high complex part with good mechanical properties, and also the ability to use many core materials, from polymers, metal alloy, ceramics or even composites materials. Due to the fact that the production of part using SLS technologies takes a long time, shows the relevance to study the entire process in order to quantify the time spent in each stage a very important step. This study can be conducted with two major goals, in one hand to be able to predict the build time needed to complete a predetermined task, and in other hand, to improve the overall efficiency of the process based on the knowledge acquired in the previous analysis. These two aspects are important because they allow the machine operator to choose the production plan more carefully and also to know all the parameters of the process to make it more efficient. In this paper will be presented a survey of the major stages of a SLS process in order to quantify the time consumed in each one of the stages, and if possible, determine solution to reduce the time spent. To better understand the topic the paper will be divided according to the proprieties and time consumed in each of the elements of the process. In other words, it will be divided accordingly to a machine, laser and material point of view. Furthermore, this paper will be focused in the SLS process and the productions based in a polymeric powder, therefore also containing aspects related to the power source used.

Study Regarding the Influence of the Printing Orientation Angle on the Mechanical Behavior of Parts Manufactured by Material Jetting

2021 ◽  
Vol 58 (3) ◽  
pp. 198-209
Author(s):  
Vasile Cojocaru ◽  
Doina Frunzaverde ◽  
Dorian Nedelcu ◽  
Calin-Octavian Miclosina ◽  
Gabriela Marginean
Keyword(s):  
Additive Manufacturing ◽  
Rapid Prototyping ◽  
Tensile Test ◽  
Mechanical Behavior ◽  
Process Parameters ◽  
Orientation Angle ◽  
Tensile Tests ◽  
Anisotropic Behavior ◽  
Optimization Of Process Parameters ◽  
Printed Materials

Initially developed as a rapid prototyping tool for project visualization and validation, the recent development of additive manufacturing (AM) technologies has led to the transition from rapid prototyping to rapid manufacturing. As a consequence, increased attention has to be paid to the mechanical, chemical and physical properties of the printed materials. In mechanical engineering, the widespread use of AM technologies requires the optimization of process parameters and material properties in order to obtain components with high, repeatable and time-stable mechanical properties. One of the main problems in this regard is the anisotropic behavior of components made by additive manufacturing, determined by the type of material, the 3D printing technology, the process parameters and the position of the components in the printing space. In this paper the influence of the printing orientation angle on the tensile behavior of specimens made by material jetting is investigated. The aim was to determine if the positioning of components at different angles relative to the X-axis of the printer (and implicitly in relation to the multijet printing head) contributes to anisotropic behavior. The material used was a photopolymer with a mechanical strength between 40 MPa and 55 MPa, according to the producer. Four sets of tensile test specimens were manufactured, using flat build orientation and positioned on the printing table at angles of 0˚, 30˚, 60˚ and 90˚ to the X-axis of the printer. Comparative analysis of the mechanical behavior was carried out by tensile tests and microscopic investigations of the tensile test specimens fracture surfaces.

Development of 3D Finite Element Model for Predicting Process-Induced Defects in Additive Manufacturing by Selective Laser Melting (SLM)

2016 ◽  
Author(s):  
Bilal Hussain ◽  
A. Sherif El-Gizawy
Keyword(s):  
Additive Manufacturing ◽  
Laser Beam ◽  
Selective Laser Melting ◽  
Thermal Stresses ◽  
Cost Effective ◽  
Element Model ◽  
Laser Melting ◽  
Two Phase ◽  
Free Process ◽  
Manufacturing Techniques

Selective Laser Melting (SLM) is one of the important Additive Manufacturing techniques for building functional products. Nevertheless, the absence of accurate models for predicting the SLM process behavior, delays development of cost effective and defects free process. This work presents a coupled thermo-mechanical numerical model to capture the two phase (solid-liquid) solidification melting phenomena that occur in the process. The proposed model will also predict the evolvement of process-induced properties and defects particularly residual stresses caused by temperature gradient and thermal stresses. CO2 or Nd:YAG laser beam can be used as a heat source with a Gaussian distribution for the laser beam energy.

scholarly journals Roadmap for Additive Manufacturing of Haynes® 282® Superalloy by Laser Beam Powder Bed Fusion (PBF-LB) Technology

2020 ◽  
Author(s):  
Robert Otto ◽  
Vegard Brøtan ◽  
Patricia Almeida Carvalho ◽  
Magnus Reiersen ◽  
Joachim Seland Graff ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Laser Beam ◽  
Powder Bed Fusion ◽  
Powder Bed
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