Multi-objective optimization of LPBF manufacturing with Zn-4Al-1Cu alloy for technical applications

IF 6.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Journal of Manufacturing Processes Pub Date : 2025-01-31 DOI:10.1016/j.jmapro.2024.12.049

Alexander Heiss , Venkat Sai Thatikonda , Ulrich E. Klotz

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Abstract

Cost-utility analyses vary by application. Regarding laser powder bed fusion (LPBF) manufacturing with zinc for technical applications, however, quality, production costs, and sustainability require distinct evaluation. The narrow process window of LPBF with zinc alloys, due to their low melting point, poses challenges, yet dense parts (> 99 %) were successfully produced, albeit with high costs and occasional quality variations. Commercial LPBF manufacturing demands stable processes for consistent quality. A controlled porosity may be acceptable based on specifications. This study presents a multi-objective optimization of LPBF manufacturing with the Zn alloy Z410. We examined the microstructure and pore morphology of 45 test parts, and applied unsupervised machine learning with principal component analysis to evaluate the process parameter space for density, pore size, and shape, creating process maps. The optimal laser parameters were then used to fabricate a demonstrator as proof of concept.

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来源期刊

Journal of Manufacturing Processes ENGINEERING, MANUFACTURING-

CiteScore

10.20

自引率

11.30%

发文量

833

审稿时长

50 days

期刊介绍： The aim of the Journal of Manufacturing Processes (JMP) is to exchange current and future directions of manufacturing processes research, development and implementation, and to publish archival scholarly literature with a view to advancing state-of-the-art manufacturing processes and encouraging innovation for developing new and efficient processes. The journal will also publish from other research communities for rapid communication of innovative new concepts. Special-topic issues on emerging technologies and invited papers will also be published.