scholarly journals Nanoparticle Additivation Effects on Laser Powder Bed Fusion of Metals and Polymers—A Theoretical Concept for an Inter-Laboratory Study Design All Along the Process Chain, Including Research Data Management

Materials ◽  
2021 ◽  
Vol 14 (17) ◽  
pp. 4892
Author(s):  
Ihsan Murat Kusoglu ◽  
Florian Huber ◽  
Carlos Doñate-Buendía ◽  
Anna Rosa Ziefuss ◽  
Bilal Gökce ◽  
...  
Keyword(s):  
Research Data ◽  
Powder Bed Fusion ◽  
Process Chain ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Research Data Management ◽  
Polymer Powder ◽  
Powder Feedstock ◽  
Repeatability And Reproducibility ◽  
Material Process

In recent years, the application field of laser powder bed fusion of metals and polymers extends through an increasing variability of powder compositions in the market. New powder formulations such as nanoparticle (NP) additivated powder feedstocks are available today. Interestingly, they behave differently along with the entire laser powder bed fusion (PBF-LB) process chain, from flowability over absorbance and microstructure formation to processability and final part properties. Recent studies show that supporting NPs on metal and polymer powder feedstocks enhances processability, avoids crack formation, refines grain size, increases functionality, and improves as-built part properties. Although several inter-laboratory studies (ILSs) on metal and polymer PBF-LB exist, they mainly focus on mechanical properties and primarily ignore nano-additivated feedstocks or standardized assessment of powder feedstock properties. However, those studies must obtain reliable data to validate each property metric’s repeatability and reproducibility limits related to the PBF-LB process chain. We herein propose the design of a large-scale ILS to quantify the effect of nanoparticle additivation on powder characteristics, process behavior, microstructure, and part properties in PBF-LB. Besides the work and sample flow to organize the ILS, the test methods to measure the NP-additivated metal and polymer powder feedstock properties and resulting part properties are defined. A research data management (RDM) plan is designed to extract scientific results from the vast amount of material, process, and part data. The RDM focuses not only on the repeatability and reproducibility of a metric but also on the FAIR principle to include findable, accessible, interoperable, and reusable data/meta-data in additive manufacturing. The proposed ILS design gives access to principal component analysis (PCA) to compute the correlations between the material–process–microstructure–part properties.

scholarly journals Laser Powder Bed Fusion of Polymers: Quantitative Research Direction Indices

Materials ◽  
2021 ◽  
Vol 14 (5) ◽  
pp. 1169 ◽  
Author(s):  
Ihsan Murat Kusoglu ◽  
Carlos Doñate-Buendía ◽  
Stephan Barcikowski ◽  
Bilal Gökce
Keyword(s):  
Energy Density ◽  
Data Matrix ◽  
Powder Layer ◽  
Automotive Electronics ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Healthcare Applications ◽  
Powder Bed ◽  
Polymer Powder ◽  
Material Process

Research on Laser Powder Bed Fusion (L-PBF) of polymer powder feedstocks has raised over the last decade due to the increased utilization of the fabricated parts in aerospace, automotive, electronics, and healthcare applications. A total of 600 Science Citation Indexed articles were published on the topic of L-PBF of polymer powder feedstocks in the last decade, being cited more than 10,000 times leading to an h-index of 46. This study statistically evaluates the 100 most cited articles to extract reported material, process, and as-built part properties to analyze the research trends. PA12, PEEK, and TPU are the most employed polymer powder feedstocks, while size, flowability, and thermal behavior are the standardly reported material properties. Likewise, process properties such as laser power, scanning speed, hatch spacing, powder layer thickness, volumetric energy density, and areal energy density are extracted and evaluated. In addition, material and process properties of the as-built parts such as tensile test, flexural test, and volumetric porosity contents are analyzed. The incorporation of additives is found to be an effective route to enhance mechanical and functional properties. Carbon-based additives are typically employed in applications where mechanical properties are essential. Carbon fibers, Ca-phosphates, and SiO2 are the most reported additives in the evaluated SCI-expanded articles for L-PBF of polymer powder feedstocks. A comprehensive data matrix is extracted from the evaluated SCI-index publications, and a principal component analysis (PCA) is performed to explore correlations between reported material, process, and as-built parts.

scholarly journals Effect of the Process Atmosphere Composition on Alloy 718 Produced by Laser Powder Bed Fusion

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1254
Author(s):  
Camille Pauzon ◽  
Andreas Markström ◽  
Sophie Dubiez-Le Goff ◽  
Eduard Hryha
Keyword(s):  
Powder Bed Fusion ◽  
Alloy 718 ◽  
Oxygen Level ◽  
Laser Powder Bed Fusion ◽  
Oxygen Loss ◽  
Powder Bed ◽  
Powder Feedstock ◽  
Traditional Manufacturing ◽  
Kinetic Calculations ◽  
Process Atmosphere

The detrimental effect of nitrogen and oxygen when it comes to the precipitation of the strengthening γ’’ and γ’ phases in Alloy 718 is well-known from traditional manufacturing. Hence, the influence of the two processing atmospheres, namely argon and nitrogen, during the laser powder bed fusion (L-PBF) of Alloy 718 parts was studied. Regardless of the gas type, considerable losses of both oxygen of about 150 ppm O2 (≈30%) and nitrogen on the level of around 400 ppm N2 (≈25%) were measured in comparison to the feedstock powder. The utilization of nitrogen as processing atmosphere led to a slightly higher nitrogen content in the as-built material—about 50 ppm—compared to the argon atmosphere. The presence of the stable nitrides and Al-rich oxides observed in the as-built material was related to the transfer of these inclusions from the nitrogen atomized powder feedstock to the components. This was confirmed by dedicated analysis of the powder feedstock and supported by thermodynamic and kinetic calculations. Rapid cooling rates were held responsible for the limited nitrogen pick-up. Oxide dissociation during laser–powder interaction, metal vaporization followed by oxidation and spatter generation, and their removal by processing atmosphere are the factors describing an important oxygen loss during L-PBF. In addition, the reduction of the oxygen level in the process atmosphere from 500 to 50 ppm resulted in the reduction in the oxygen level in as-built component by about 5%.

scholarly journals Effects on the distortion of Inconel 718 components along a hybrid laser-based additive manufacturing process chain using laser powder bed fusion and laser metal deposition

2021 ◽  
Author(s):  
Eckart Uhlmann ◽  
Jan Düchting ◽  
Torsten Petrat ◽  
Erwin Krohmer ◽  
Benjamin Graf ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Inconel 718 ◽  
Powder Bed Fusion ◽  
Laser Metal Deposition ◽  
Process Chain ◽  
Laser Powder Bed Fusion ◽  
Plate Material ◽  
Powder Bed ◽  
Manufacturing Process Chain

AbstractThe combination of laser powder bed fusion (LPBF), known for its geometrical freedom and accuracy, and the nozzle-based laser metal deposition process (LMD), known for its high build-up rates, has great potential to reduce the additive manufacturing times for large metallic parts. For the industrial application of the LPBF-LMD hybrid process chain, it is necessary to investigate the influence of the LMD process on the LPBF substrate. In addition, the build plate material also has a significant impact on the occurrence of distortion along the additive manufacturing process chain. In the literature, steel build plates are often used in laser-based additive manufacturing processes of Inconel 718, since a good metallurgical bonding can be assured whilst reducing costs in the production and restoration of the build plates. This paper examines the distortion caused by LMD material deposition and the influence of the build plate material along the hybrid additive manufacturing process chain. Twin cantilevers are manufactured by LPBF and an additional layer is subsequently deposited with LMD. The distortion is measured in the as-built condition as well as after heat treatment. The effect of different LMD hatch strategies on the distortion is determined. The experiments are conducted using the nickel-base alloy Inconel 718. The results show a significant influence of LMD path strategies on distortion, with shorter tool paths leading to less distortion. The remaining distortion after heat treatment is considerably dependent on the material of the build plate.

scholarly journals Sustainable Aspects of a Metal Printing Process Chain with Laser Powder Bed Fusion (LPBF)

Procedia CIRP ◽  
2021 ◽  
Vol 98 ◽  
pp. 613-618
Author(s):  
Dennis Ochs ◽  
Kira Kristin Wehnert ◽  
Jürgen Hartmann ◽  
Andreas Schiffler ◽  
Jan Schmitt
Keyword(s):  
Powder Bed Fusion ◽  
Process Chain ◽  
Laser Powder Bed Fusion ◽  
Printing Process ◽  
Powder Bed ◽  
Metal Printing

scholarly journals Maturity Assessment of Laser Powder Bed Fusion Process Chain Modelling and Simulation

2021 ◽  
pp. 34-45
Author(s):  
Anas Yaghi ◽  
Shukri Afazov ◽  
Matteo Villa
Keyword(s):  
Case Studies ◽  
Manufacturing Process ◽  
Modelling And Simulation ◽  
Fusion Process ◽  
Design Solution ◽  
Powder Bed Fusion ◽  
Process Chain ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Process Chains

This paper presents case studies of additive manufacturing process chains including laser powder bed fusion and post-processes. The presented case studies are used to assess the maturity of the manufacturing process chains using a Modelling and Simulation Readiness Level Scale. The results from the assessment have shown that the maturity of the modelling and simulation of laser powder bed fusion process chains lies between the stage of applied research and development and the stage of being instrumental, with high reliance on modelling and simulation experts. This means that the laser powder bed fusion (L-PBF) process chain modelling and simulation can support low-risk development, with high reliance on modelling and simulation experts, making them suitable for qualitative assessment, alternative design/solution ranking, defining the design structure, constraining the design space and replacing some experimental trials. This shows that further maturation is required before the modelling and simulation methods and codes are well recognised as best practice in the industry and are part of operational process control at any stage of the supply chain.

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