Optimizing the process parameters for additive manufacturing of glass components by selective laser melting: Soda-lime glass versus quartz glass

2021 ◽  
pp. 1-10
Author(s):  
Sergey Grigoriev ◽  
Roman Khmyrov ◽  
Mikhail Gridnev ◽  
Tatiana Tarasova ◽  
Andrey Gusarov
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Quartz Glass ◽  
Soda Lime ◽  
High Viscosity ◽  
Residual Porosity ◽  
Soda Lime Glass ◽  
Laser Melting ◽  
Powder Consolidation ◽  
Preheating Temperature

Abstract Additive manufacturing by selective laser melting (SLM) is generally applicable to glasses while insufficient resistance of the material to thermal shocks due to local laser heating may result in cracking and a high viscosity of glass melt is responsible for incomplete powder consolidation related to residual porosity. The present work shows that preheating up to 350 °C is sufficient to avoid cracking of soda-lime glass. Preheating of quartz glass up to 730 °C considerably decreases the residual porosity, which is explained by acceleration of powder consolidation by the viscous-flow mechanism of glass particles' coalescence. Variation of the preheating temperature is an effective tool to control consolidation of glass powder and to avoid cracking.

scholarly journals Modelling of Selective Laser Melting Process of Quartz Glass at Elevated Temperatures

2021 ◽  
Vol 248 ◽  
pp. 01001
Author(s):  
M.A. Gridnev ◽  
R.S. Khmyrov ◽  
A.V. Gusarov
Keyword(s):  
Selective Laser Melting ◽  
Quartz Glass ◽  
Elevated Temperatures ◽  
Melting Process ◽  
Coupled Processes ◽  
Powder Layer ◽  
Layer By Layer ◽  
Laser Melting ◽  
Material Quality ◽  
Powder Consolidation

Selective laser melting (SLM) to date is the method of additive manufacturing allowing fabricating products from powder layer-by-layer according to a 3D model. However, when applying this method to fragile materials, parts crack while fabricating due to high temperatures. Quartz glass is a promising material for fabricating products by SLM without cracks due to a low thermal expansion. However, quality of fabricated material differs from the fused cast ones. This article aims to test the method of SLM with preheating to improve the material quality. Experiments on single track formation in SLM are analysed by modelling the coupled processes of heat transfer and powder consolidation in the laser-interaction zone. The mathematical model is validated by the experiments. It is shown that the preheating can improve the material quality and increase the process productivity but overheating may result in undesirable crystallization.

scholarly journals Improving surface quality in selective laser melting based tool making

2021 ◽  
Author(s):  
Filippo Simoni ◽  
Andrea Huxol ◽  
Franz-Josef Villmer
Keyword(s):  
Surface Roughness ◽  
Additive Manufacturing ◽  
Surface Quality ◽  
Selective Laser Melting ◽  
Melting Process ◽  
Laser Remelting ◽  
Laser Melting ◽  
Great Cost ◽  
Starting Point ◽  
Processing Techniques

AbstractIn the last years, Additive Manufacturing, thanks to its capability of continuous improvements in performance and cost-efficiency, was able to partly replace and redefine well-established manufacturing processes. This research is based on the idea to achieve great cost and operational benefits especially in the field of tool making for injection molding by combining traditional and additive manufacturing in one process chain. Special attention is given to the surface quality in terms of surface roughness and its optimization directly in the Selective Laser Melting process. This article presents the possibility for a remelting process of the SLM parts as a way to optimize the surfaces of the produced parts. The influence of laser remelting on the surface roughness of the parts is analyzed while varying machine parameters like laser power and scan settings. Laser remelting with optimized parameter settings considerably improves the surface quality of SLM parts and is a great starting point for further post-processing techniques, which require a low initial value of surface roughness.

scholarly journals Directionally-Dependent Mechanical Properties of Ti6Al4V Manufactured by Electron Beam Melting (EBM) and Selective Laser Melting (SLM)

Materials ◽  
2021 ◽  
Vol 14 (13) ◽  
pp. 3603
Author(s):  
Tim Pasang ◽  
Benny Tavlovich ◽  
Omry Yannay ◽  
Ben Jakson ◽  
Mike Fry ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Tensile Strength ◽  
Electron Beam ◽  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Electron Beam Melting ◽  
Rolling Direction ◽  
Laser Melting ◽  
Plate Rolling

An investigation of mechanical properties of Ti6Al4V produced by additive manufacturing (AM) in the as-printed condition have been conducted and compared with wrought alloys. The AM samples were built by Selective Laser Melting (SLM) and Electron Beam Melting (EBM) in 0°, 45° and 90°—relative to horizontal direction. Similarly, the wrought samples were also cut and tested in the same directions relative to the plate rolling direction. The microstructures of the samples were significantly different on all samples. α′ martensite was observed on the SLM, acicular α on EBM and combination of both on the wrought alloy. EBM samples had higher surface roughness (Ra) compared with both SLM and wrought alloy. SLM samples were comparatively harder than wrought alloy and EBM. Tensile strength of the wrought alloy was higher in all directions except for 45°, where SLM samples showed higher strength than both EBM and wrought alloy on that direction. The ductility of the wrought alloy was consistently higher than both SLM and EBM indicated by clear necking feature on the wrought alloy samples. Dimples were observed on all fracture surfaces.

scholarly journals Selective Laser Melting of Crack-Free High Density M2 High Speed Steel Parts by Baseplate Preheating

2014 ◽  
Vol 136 (6) ◽  
Author(s):  
Karolien Kempen ◽  
Bey Vrancken ◽  
Sam Buls ◽  
Lore Thijs ◽  
Jan Van Humbeeck ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
High Speed ◽  
Crack Formation ◽  
High Speed Steel ◽  
Thermal Gradients ◽  
Laser Melting ◽  
Mechanical And Physical Properties ◽  
The World ◽  
M2 High Speed Steel

Cracks and delamination, resulting from residual stresses, are a barrier in the world of additive manufacturing and selective laser melting (SLM) that prohibits the use of many metals in this field. By preheating the baseplate, thermal gradients are lowered and stresses can be reduced. In this work, some initial tests were performed with M2 high speed steel (HSS). The influence of preheating on density and mechanical and physical properties is investigated. The paper shows many promising results for the production of SLM parts in materials that are very sensitive to crack formation and delamination. When using a preheating of 200 °C, crack-free M2 HSS parts were produced with a relative density of 99.8%.

Einbringen von Gewinden in SLM-Bauteile*/Insertion of threads into SLM components – Reliable strategy for inserting threads into additively manufactured components

2019 ◽  
Vol 109 (01-02) ◽  
pp. 24-29
Author(s):  
E. Abele ◽  
T. Scherer ◽  
F. Geßner ◽  
M. Weigold
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Downstream Processing ◽  
Manufacturing Processes ◽  
Laser Melting ◽  
Manufacturing Costs ◽  
Process Reliability ◽  
High Degree ◽  
Design Freedom ◽  
Processing Steps

Additive Fertigungsverfahren zeichnen sich durch große Gestaltungsfreiheit aus, welche die Herstellung komplexer Bauteile ermöglicht. Angesichts hoher Fertigungskosten ist die Prozesssicherheit nachgeordneter Bearbeitungsschritte (wie zum Beispiel die Gewindefertigung) von großer Bedeutung. Der Artikel stellt die Ergebnisse einer Untersuchungsreihe vor, die unterschiedliche Ansätze der Gewindefertigung in Bauteilen aus Stahl behandelt, die mittels Selektivem Laserschmelzverfahren gefertigt wurden.   Additive manufacturing processes are characterized by a high degree of design freedom to enablet the production of complex components. To reduce manufacturing costs, the process reliability of downstream processing steps (e. g. thread production) is of great importance. This article presents the results of a series of investigations dealing with different approaches to thread production in steel components manufactured by selective laser melting

ANISOTROPIC CUTTING FORCE CHARACTERISTICS IN MILLING OF MARAGING STEEL PROCESSED THROUGH SELECTIVE LASER MELTING

2021 ◽  
pp. 1-16
Author(s):  
Shoichi Tamura ◽  
Takashi Matsumura ◽  
Atsushi Ezura ◽  
Kazuo Mori
Keyword(s):  
Additive Manufacturing ◽  
Cutting Force ◽  
Maraging Steel ◽  
Selective Laser Melting ◽  
Cutting Forces ◽  
Manufacturing Process ◽  
Laser Scanning ◽  
Force Model ◽  
Laser Melting ◽  
Scanning Direction

Abstract Additive manufacturing process of maraging steel has been studied for high value parts in aerospace and automotive industries. The hybrid additive / subtractive manufacturing is effective to achieve tight tolerances and surface finishes. The additive process induces anisotropic mechanical properties of maraging steel, which depends on the laser scanning direction. Because anisotropy in the workpiece material has an influence on the cutting process, the surface finish and the dimension accuracy change according to the direction of the cutter feed with respect to the laser scanning direction. Therefore, the cutting parameters should be determined to control the cutting force considering material anisotropy. The paper discusses the cutting force in milling of maraging steel stacked with selective laser melting, as an additive manufacturing process. Anisotropic effect on the cutting forces is proved with the changing rate of the cutting force in milling of the workpieces stacked by repeating laser scanning at 0/90 degrees and 45/-45 degrees. The cutting forces, then, are analyzed in the chip flow models with piling up of orthogonal cuttings. The force model associates anisotropy with the shear stress on the shear plane. The changes in the cutting forces with the feed direction are discussed in the cutting tests and analysis.

Properties of aluminum metal matrix composites manufactured by selective laser melting

2021 ◽  
Vol 112 (7) ◽  
pp. 552-564
Author(s):  
Christian Felber ◽  
Florian Rödl ◽  
Ferdinand Haider
Keyword(s):  
Additive Manufacturing ◽  
Aluminum Alloys ◽  
Selective Laser Melting ◽  
Metal Matrix ◽  
High Hardness ◽  
High Strength ◽  
Laser Melting ◽  
Scanning Calorimetry ◽  
Particle Reinforcement ◽  
The Matrix

Abstract The most promising metal processing additive manufacturing technique in industry is selective laser melting, but only a few alloys are commercially available, limiting the potential of this technique. In particular high strength aluminum alloys, which are of great importance in the automotive industry, are missing. An aluminum 2024 alloy, reinforced by Ti-6Al-4V and B4C particles, could be used as a high strength alternative for aluminum alloys. Heat treating can be used to improve the mechanical properties of the metal matrix composite. Dynamic scanning calorimetry shows the formation of Al2Cu precipitates in the matrix instead of the expected Al2CuMg phases due to the loss of magnesium during printing, and precipitation processes are accelerated due to particle reinforcement and additive manufacturing. Strong reactions between aluminum and Ti-6Al-4V are observed in the microstructure, while B4C shows no reaction with the matrix or the titanium. The material shows high hardness, high stiffness, and low ductility through precipitation and particle reinforcement.

Size effect in selective laser melting additive manufacturing of 700 mm large component

2022 ◽  
Vol 75 ◽  
pp. 125-137
Author(s):  
Haolin Jia ◽  
Hua Sun ◽  
Hongze Wang ◽  
Yi Wu ◽  
Haowei Wang
Keyword(s):  
Additive Manufacturing ◽  
Size Effect ◽  
Selective Laser Melting ◽  
Laser Melting ◽  
Large Component
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