On the limitations of small cubes as test coupons for process parameter optimization in laser powder bed fusion of metals

IF 1.7 4区 工程技术 Q3 MATERIALS SCIENCE, MULTIDISCIPLINARY
Gunther Mohr, Simon J. Altenburg, Kai Hilgenberg
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引用次数: 0

Abstract

The capability to produce complexly and individually shaped metallic parts is one of the main advantages of the laser powder bed fusion process. Development of material and machine specific process parameters is commonly based on the results acquired from small cubic test coupons of ∼10 mm edge length. Such cubes are usually used to conduct the optimization of process parameters to produce dense materials. The parameters are then taken as the basis for the manufacturing of real part geometries. However, complex geometries go along with complex thermal histories during the manufacturing process, which can significantly differ from thermal conditions prevalent during the production of simply shaped test coupons. This may lead to unexpected and unpredicted local inhomogeneities of the microstructure and defect distribution in the final part, and it is a root cause of reservations against the use of additive manufacturing for the production of safety relevant parts. In this study, the influence of changing thermal conditions on the resulting melt pool depth of 316L stainless steel specimens is demonstrated. A variation in thermographically measured intrinsic preheating temperatures was triggered by the alteration of interlayer times and a variation in cross-sectional areas of specimens for three distinct sets of process parameters. Correlations between the preheating temperature, the melt pool depth, and occurring defects were analyzed. The limited expressiveness of the results of small density cubes is revealed throughout the systematic investigation. Finally, a clear recommendation to consider thermal conditions in future process parameter optimizations is given.
激光粉末床金属熔合工艺参数优化中小立方体作为试样的局限性
激光粉末床熔合工艺的主要优点之一是能够生产复杂和独立形状的金属零件。材料和机器特定工艺参数的开发通常基于边长约10毫米的小立方测试片获得的结果。这种立方体通常用于工艺参数的优化,以生产致密材料。然后将这些参数作为制造实际零件几何形状的基础。然而,在制造过程中,复杂的几何形状伴随着复杂的热历史,这与简单成型测试板生产过程中普遍存在的热条件有很大不同。这可能会导致最终零件的微观结构和缺陷分布出现意想不到和无法预测的局部不均匀性,这是反对使用增材制造生产安全相关零件的根本原因。在本研究中,研究了热条件的变化对316L不锈钢试样熔池深度的影响。热成像测量的固有预热温度的变化是由层间时间的改变和三组不同工艺参数下试样横截面积的变化引起的。分析了预热温度、熔池深度与发生缺陷之间的关系。在整个系统调查中揭示了小密度立方体结果的有限表达性。最后,给出了在未来工艺参数优化中考虑热条件的明确建议。
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来源期刊
CiteScore
3.60
自引率
9.50%
发文量
125
审稿时长
>12 weeks
期刊介绍: The Journal of Laser Applications (JLA) is the scientific platform of the Laser Institute of America (LIA) and is published in cooperation with AIP Publishing. The high-quality articles cover a broad range from fundamental and applied research and development to industrial applications. Therefore, JLA is a reflection of the state-of-R&D in photonic production, sensing and measurement as well as Laser safety. The following international and well known first-class scientists serve as allocated Editors in 9 new categories: High Precision Materials Processing with Ultrafast Lasers Laser Additive Manufacturing High Power Materials Processing with High Brightness Lasers Emerging Applications of Laser Technologies in High-performance/Multi-function Materials and Structures Surface Modification Lasers in Nanomanufacturing / Nanophotonics & Thin Film Technology Spectroscopy / Imaging / Diagnostics / Measurements Laser Systems and Markets Medical Applications & Safety Thermal Transportation Nanomaterials and Nanoprocessing Laser applications in Microelectronics.
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