scholarly journals A Prediction Model for Additive Manufacturing of Inconel 718 Superalloy

2021 ◽  
Vol 11 (17) ◽  
pp. 8010
Author(s):  
Bharath Bhushan Ravichander ◽  
Atabak Rahimzadeh ◽  
Behzad Farhang ◽  
Narges Shayesteh Moghaddam ◽  
Amirhesam Amerinatanzi ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Prediction Model ◽  
Process Parameters ◽  
Inconel 718 ◽  
Oil And Gas ◽  
Surface Hardness ◽  
Scanning Speed ◽  
Optimal Process ◽  
Ann Modeling ◽  
Sample Height

Inconel 718 is a nickel-based superalloy and an excellent candidate for the aerospace, oil, and gas industries due to its high strength and corrosion resistance properties. The machining of IN718 is very challenging; therefore, the application of additive manufacturing (AM) technology is an effective approach to overcoming these difficulties and for the fabrication of complex geometries that cannot be manufactured by the traditional techniques. Selective laser melting (SLM), which is a laser powder bed fusion method, can be applied for the fabrication of IN718 samples with high accuracy. However, the process parameters have a high impact on the properties of the manufactured samples. In this study, a prediction model is developed for obtaining the optimal process parameters, including laser power, hatch spacing, and scanning speed, in the SLM process of the IN718 alloy. For this purpose, artificial neural network (ANN) modeling with various algorithms is employed to estimate the process outputs, namely, sample height and surface hardness. The modeling results fit perfectly with the experimental output, and this consequently proves the benefit of ANN modeling for predicting the optimal process parameters.

scholarly journals Optimization of SLS forming parameters in the dimensional accuracy of formed parts

2021 ◽  
Vol 233 ◽  
pp. 01069
Author(s):  
Hong ZHU ◽  
Gaoyan HOU
Keyword(s):  
Process Parameters ◽  
Selective Laser Sintering ◽  
Dimensional Accuracy ◽  
Scanning Speed ◽  
Axis Deviation ◽  
Reference Standard ◽  
Optimal Process ◽  
Molded Part ◽  
Formed Part ◽  
Powder Forming

In selective laser sintering powder forming, the performance and dimensional accuracy of the formed part are affected by the process parameters. Different materials have different process parameters, and there is still no reference standard for PA materials. To solve this problem, in response to this problem, PA2200 material was selected, and the influence of scanning interval and scanning speed on the dimensional accuracy of the formed part was analyzed. Through theoretical analysis and experiments, the optimal process parameters were obtained. The best combination of parameters is a scanning speed of 4000mm/s, a scanning interval of 0.5mm, and the size of the molded part has a X-axis deviation -0.35%, a Y-axis deviation -0.4%, and a Z-axis deviation -0.25%.

scholarly journals Multi-objective numerical simulation of geometrical characteristics of laser cladding of cobalt-based alloy based on response surface methodology

2020 ◽  
pp. 002029402094495
Author(s):  
Lu-jun Cui ◽  
Meng Zhang ◽  
Shi-Rui Guo ◽  
Yan-Long Cao ◽  
Wen-Han Zeng ◽  
...  
Keyword(s):  
Prediction Model ◽  
Response Surface ◽  
Laser Cladding ◽  
Process Parameters ◽  
Laser Power ◽  
Influence Factors ◽  
Scanning Speed ◽  
Laser Cladding Remanufacturing ◽  
Main Influence

The objectives of this study are to optimize the key process parameters of laser cladding remanufacturing parts, improve the sealing quality of the hemispherical valve and prolong and improve its service life and reliability. A high-power fiber-coupled semiconductor laser was used to fabricate a single Co-based alloy cladding layer on the pump valve material ZG45 plate. The key process parameters of laser power, scanning speed and powder feeding rate in the process of laser remanufacturing are taken as optimization variables, and the coating width, coating height, coating depth, aspect ratio and dilution rate are taken as response indexes. Based on the response surface analysis method, the central compound experiment is designed using Design-Expert software. The variance analysis of the experimental results is performed, and the regression prediction model of the process parameters relative to the corresponding index is established. Through analysis of the established perturbation diagram and three-dimensional response surface, it is concluded that the main influence factors of melting width and penetration depth are laser power and positive effect, and the main influence factors of melting height are scanning speed and negative effect. The average error of each regression prediction model is lower than 10%. The above research work has important guiding significance for optimizing the process parameters and improving the cladding quality of cobalt-based alloy on ZG45.

A Sensitivity Analysis Study on the Material Properties and Process Parameters for Selective Laser Melting of Inconel 625

2015 ◽  
Author(s):  
Luis E. Criales ◽  
Yiğit M. Arısoy ◽  
Tuğrul Özel
Keyword(s):  
Additive Manufacturing ◽  
Selective Laser Melting ◽  
Process Parameters ◽  
Scanning Speed ◽  
Inconel 625 ◽  
Pool Data ◽  
Temperature Profiles ◽  
Laser Melting ◽  
Melt Pool ◽  
Laser Heat Source

A prediction of the 2-D temperature profile and melt pool geometry for Selective Laser Melting (SLM) of Inconel 625 metal powder with a numerically-based approach for solving the heat conduction-diffusion equation was established in this paper. A finite element method solution of the governing equation was developed. A review of the current efforts in numerical modeling for laser-based additive manufacturing is presented. Initially, two-dimensional (2-D) temperature profiles along the scanning (x-direction) and hatch direction (y-direction) are calculated for a moving laser heat source to understand the temperature rise due to heating during SLM. The effects of varying laser power, scanning speed and the powder material’s density are analyzed. Based on the predicted temperature distributions, melt pool geometry, i.e. the locations at which melting of the powder material occurs, is determined. The results are chiefly compared against the published literature on melt pool data. The main goal of this research is to develop a computational tool with which investigation of the importance of various laser, material, and process parameters on the built dimensional quality in laser-based additive manufacturing becomes not only possible but also practical and reproducible.

Role of process parameters during additive manufacturing by direct metal deposition of Inconel 718

2017 ◽  
Vol 23 (5) ◽  
pp. 919-929 ◽  
Author(s):  
Bo Chen ◽  
Jyoti Mazumder
Keyword(s):  
Additive Manufacturing ◽  
Cooling Rate ◽  
Process Parameters ◽  
Manufacturing Process ◽  
Inconel 718 ◽  
Processing Parameters ◽  
Forming Quality ◽  
Content Type ◽  
Forming Characteristics ◽  
The Relationship

Purpose The aim of this research is to study the influence of laser additive manufacturing process parameters on the deposit formation characteristics of Inconel 718 superalloy, the main parameters that influence the forming characteristics, the cooling rate and the microstructure were studied. Design/methodology/approach Orthogonal experiment design method was used to obtain different deposit shape and microstructure using different process parameters by multiple layers deposition. The relationship between the processing parameters and the geometry of the cladding was analyzed, and the dominant parameters that influenced the cladding width and height were identified. The cooling rates of different forming conditions were obtained by the secondary dendrite arm spacing (SDAS). Findings The microstructure showed different characteristics at different parts of the deposit. Cooling rate of different samples were obtained and compared by using the SDAS, and the influence of the process parameters to the cooling rate was analyzed. Finally, micro-hardness tests were done, and the results were found to be in accordance with the micro-structure distribution. Originality/value Relationships between processing parameters and the forming characteristics and the cooling rates were obtained. The results obtained in this paper will help to understand the relationship between the process parameters and the forming quality of the additive manufacturing process, so as to obtain the desired forming quality by appropriate parameters.

scholarly journals Prediction for Dilution Rate of AlCoCrFeNi Coatings by Laser Cladding Based on a BP Neural Network

Coatings ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1402
Author(s):  
Yutao Li ◽  
Kaiming Wang ◽  
Hanguang Fu ◽  
Xiaohui Zhi ◽  
Xingye Guo ◽  
...  
Keyword(s):  
Neural Network ◽  
Dilution Rate ◽  
Process Parameters ◽  
Bp Neural Network ◽  
Orthogonal Experiment ◽  
Scanning Speed ◽  
Good Prediction ◽  
Optimal Process ◽  
Orthogonal Experiments ◽  
Fcc Phase

The dilution rate has a significant impact on the composition and microstructure of the coatings, and the dilution rate and process parameters have a complex coupling relationship. In this study, three process parameters, namely laser power, powder feeding rate, and scanning speed, were selected as variables to design the orthogonal experiment. The dilution rate and hardness data were obtained from AlCoCrFeNi coatings based on orthogonal experiments. Then, a BP neural network was used to establish a prediction model of the process parameters on the dilution rate. The established BP neural network exhibited good prediction of the dilution rate of AlCoCrFeNi coatings, and the average relative error between the predicted value and the experimental value was only 5.89%. Subsequently, the AlCoCrFeNi coating was fabricated with the optimal process parameters. The results show that the coating was well-formed without defects, such as cracks and pores. The microhardness of the AlCoCrFeNi coating prepared with the optimal process parameters was 521.6 HV0.3. The elements were uniformly distributed in the microstructure, and the grain size was about 20–60 μm. The microstructure of the AlCoCrFeNi coating was only composed of the BCC phase without the existence of the FCC phase and intermetallic compounds.

scholarly journals Direct Laser Metal Deposition (DLMD) Additive Manufacturing (AM)of Inconel 718 Superalloy: Elemental, Microstructural and Physical Properties Evaluation

2021 ◽  
Author(s):  
Mahmoud Moradi ◽  
Zeynab Pourmand ◽  
Arman Hasani ◽  
Mojtaba Karami Moghadam ◽  
Amir Hosein Sakhaei ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Feed Rate ◽  
Inconel 718 ◽  
Scanning Speed ◽  
Laser Metal Deposition ◽  
Powder Feed Rate ◽  
Direct Laser ◽  
Inconel 718 Superalloy ◽  
The Stability ◽  
Direct Laser Metal Deposition

Abstract In this study direct laser metal deposition (DLMD) technique is adopted for the additive manufacturing (AM) of Inconel 718 Superalloy. To conduct the experiments, a 1 kW fiber laser with a coaxial nozzle head is used. The effects of scanning speed (for two values of 2.5 and 5 mm/s) as well as powder feed rate (for two values of 17.94 and 28.52 g/min) on the process were investigated. Characteristics of the 3D printed wall specimens such as the geometrical dimensions (width and height), microstructure observations, and the microhardness were obtained. In order to study the stability of the 3D manufactured walls, the height stability was considered for the investigation. Optical microscopy (OM), field emission electron microscopy (FE-SEM), energy dispersive X-ray spectroscopy (EDS), and mapping analysis were performed to derive the microstructural features of the additive manufactured samples. The Vickers microhardness test is used to evaluate the hardness distributions of additively manufactured parts. Catchment concept of the powder in DLMD process is used for explaining different trends of the process. Results indicated that, by decreasing the scanning speed, the width and height of the deposited layer increase. The average width of the additively manufactured samples directly depends on the scanning speed and the powder feed rate. Scanning speed has a reverse effect on the height stability; that is, the lower the scanning speed, the larger the stability. Microstructural results showed that because of the solidification process, the alloying elements will be accumulated in the grain boundaries. The non-uniform cooling rate and non-steady solidification rates of molten area in additive manufacturing process, the microhardness values of the additively manufactured samples following a fluctuated trend.

scholarly journals Selection of Optimal Process Parameters for Wire Arc Additive Manufacturing

Procedia CIRP ◽  
2017 ◽  
Vol 62 ◽  
pp. 470-474 ◽  
Author(s):  
Mariacira Liberini ◽  
Antonello Astarita ◽  
Gianni Campatelli ◽  
Antonio Scippa ◽  
Filippo Montevecchi ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Optimal Process ◽  
Wire Arc Additive Manufacturing ◽  
Selection Of

scholarly journals Influence of Powder Deposition on Powder Bed and Specimen Properties

Materials ◽  
2019 ◽  
Vol 12 (2) ◽  
pp. 297 ◽  
Author(s):  
Steffen Beitz ◽  
Roland Uerlich ◽  
Tjorben Bokelmann ◽  
Alexander Diener ◽  
Thomas Vietor ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
Surface Roughness ◽  
Additive Manufacturing ◽  
Process Parameters ◽  
Laser Scanning ◽  
Scanning Speed ◽  
Confocal Laser ◽  
Micro Computed Tomography ◽  
Powder Bed ◽  
Powder Deposition

Three-dimensional printing used to be a rapid prototyping process, but nowadays it is establishing as an additive manufacturing (AM) process. One of these AM techniques is selective laser sintering (SLS), which most often involves partial melting of the particles and therefore belongs to the category of powder bed fusion processes. Much progress has been made in this field by research on process parameters like laser power, hatch distance, and scanning speed while still lacking a fundamental understanding of the powder deposition and its influence on parts. A critical issue for economic manufacturing is the building time of parts with good mechanical properties, which can be reduced by lower surface roughness due to less or missing post processing. Therefore, the influence of three blade shapes on powder bed surface roughness has been evaluated for PA12 powder with three different grain size distributions by using advanced X-ray micro computed tomography (XMT) and a confocal laser scanning microscope (LSM). Along with those methods, new techniques for powder characterization were tested and compared. Lowest roughness has been achieved with a flat blade, based on a higher compression due to a larger contact zone between blade and powder bed. Furthermore, an anisotropic effect of the mechanical properties resulting from different building directions has been detected which can be explained by varying amounts of solid contact paths through the powder bed depending on powder application direction. In addition, an optimal combination of process parameters with an even compression of the powder bed leads to low surface roughness, complementing the advantages of additive manufacturing.

scholarly journals Additive Manufacturing of Polypropylene: a Screening Design of Experiment Using Laser-Based Powder Bed Fusion

2018 ◽  
Author(s):  
Inigo Flores Ituarte ◽  
Olli Wiikinkoski ◽  
Anton Jansson
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Design Of Experiment ◽  
Manufacturing Industry ◽  
Tensile Elongation ◽  
Scanning Speed ◽  
Process Window ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
The Impact

The use of commodity polymers such as polypropylene (PP) is key to open new market segments and applications for the additive manufacturing industry. Technologies such as powder-bed fusion (PBF) can process PP powder; however, much is still to learn concerning process parameters for reliable manufacturing. This study focusses in the process-property relationships of PP using laser-based PBF. The research presents an overview of the intrinsic and the extrinsic characteristic of a commercial PP powder as well as fabrication of tensile specimens with varying process parameters to characterize tensile, elongation at break, and porosity properties. The impact of key process parameters, such as power and scanning speed are systematically modified in a controlled design of experiment. The results were compared to the existing body of knowledge; the outcome is to present a process window and optimal process parameters for industrial use of PP. The computer tomography data revealed a highly porous structure inside specimens ranging between 8.46% and 10.08%, with porosity concentrated in the interlayer planes in the build direction. The results of the design of experiment for this commercial material show a narrow window of 0.122 ≥ Ev ≥ 0.138 J/mm3 led to increased mechanical properties while maintaining geometrical stability.

scholarly journals Additive Manufacturing of Polypropylene: A Screening Design of Experiment Using Laser-Based Powder Bed Fusion

Polymers ◽  
2018 ◽  
Vol 10 (12) ◽  
pp. 1293 ◽  
Author(s):  
Iñigo Flores Ituarte ◽  
Olli Wiikinkoski ◽  
Anton Jansson
Keyword(s):  
Additive Manufacturing ◽  
Process Parameters ◽  
Design Of Experiment ◽  
Manufacturing Industry ◽  
Tensile Elongation ◽  
Scanning Speed ◽  
Process Window ◽  
Powder Bed Fusion ◽  
Powder Bed ◽  
The Impact

The use of commodity polymers such as polypropylene (PP) is key to open new market segments and applications for the additive manufacturing industry. Technologies such as powder-bed fusion (PBF) can process PP powder; however, much is still to learn concerning process parameters for reliable manufacturing. This study focusses in the process–property relationships of PP using laser-based PBF. The research presents an overview of the intrinsic and the extrinsic characteristic of a commercial PP powder as well as fabrication of tensile specimens with varying process parameters to characterize tensile, elongation at break, and porosity properties. The impact of key process parameters, such as power and scanning speed, are systematically modified in a controlled design of experiment. The results were compared to the existing body of knowledge; the outcome is to present a process window and optimal process parameters for industrial use of PP. The computer tomography data revealed a highly porous structure inside specimens ranging between 8.46% and 10.08%, with porosity concentrated in the interlayer planes in the build direction. The results of the design of experiment for this commercial material show a narrow window of 0.122 ≥ Ev ≥ 0.138 J/mm3 led to increased mechanical properties while maintaining geometrical stability.

Sign in / Sign up

Export Citation Format

Share Document