Towards a Sustainable Laser Powder Bed Fusion Process via the Characterisation of Additively Manufactured Nitinol Parts

Designs Pub Date : 2024-05-15 DOI:10.3390/designs8030045
M. Obeidi, Paul Healy, Hasan Alobaidi, Declan Bourke, D. Brabazon
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Abstract

Is additive manufacturing (AM) a sustainable process? Can the process be optimised to produce sustainable AM parts and production techniques? Additive manufacturing offers the production of parts made of different types of materials in addition to the complex geometry that is difficult or impossible to produce by using the traditional subtractive methods. This study is focused on the optimisation of laser powder bed fusion (L-PBF), one of the most common technologies used in additive manufacturing and 3D printing. This research was carried out by modulating the build layer thickness of the deposited metal powder and the input volumetric energy density. The aim of the proposed strategy is to save the build time by maximizing the applied layer thickness of nitinol powder while retrieving the different AM part properties. The saving in the process time has a direct effect on the total cost of the produced part as a result of several components like electric energy, inert gas consumption, and labour. Nickel-rich nitinol (52.39 Ni at.%) was selected for investigation in this study due to its extremely high superplastic and shape memory properties in addition to the wide application in various industries like aerospace, biomedical, and automotive. The results obtained show that significant energy and material consumption can be found by producing near full dens AM parts with limited or no alteration in chemical and mechanical properties.
通过表征快速制造的镍钛诺部件实现可持续的激光粉末床融合工艺
快速成型制造(AM)是一种可持续工艺吗?能否对工艺进行优化,以生产可持续的增材制造部件和生产技术?除了传统的减材制造方法难以或无法生产的复杂几何形状之外,快速成型制造还能生产由不同类型材料制成的零件。本研究的重点是激光粉末床熔融(L-PBF)的优化,这是增材制造和三维打印中最常用的技术之一。这项研究是通过调节沉积金属粉末的构建层厚度和输入体积能量密度来实现的。所提出策略的目的是通过最大限度地增加镍钛诺粉末的应用层厚度来节省构建时间,同时获得不同的增材制造部件特性。由于电能、惰性气体消耗和劳动力等多个因素的影响,工艺时间的节省直接影响到生产零件的总成本。本研究选择富含镍的镍钛醇(镍含量为 52.39%)作为研究对象,这是因为镍钛醇具有极高的超塑性和形状记忆特性,而且在航空航天、生物医学和汽车等各行各业都有广泛应用。研究结果表明,通过生产接近全密度的 AM 零件,可以节省大量能源和材料,同时化学和机械性能的改变有限或没有改变。
本文章由计算机程序翻译,如有差异,请以英文原文为准。
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