Abstract
In spite of the fast growth of laser-based powder bed fusion (L-PBF) processes as a part of everyday industrial practice, achieving consistent production is hampered by the scarce repeatability of performance that is often encountered across different additive manufacturing (AM) machines. In addition, the development of novel feedstock materials, which is fundamental to the future growth of AM, is limited by the absence of established methodologies for their successful exploitation. This paper proposes a structured procedure with a complete test plan, which defines step-by-step the standardized actions that should be taken to optimize the processing parameters and scanning strategy in L-PBF of new alloy grades. The method is holistic, since it considers all the laser/material interactions in different local geometries of the build, and suggests, for each possible interaction, a specific geometry for test specimens, standard energy parameters to be analyzed through a design of experiment, and measurable key performance indicators. The proposed procedure therefore represents a sound and robust aid to the development of novel alloy grades for L-PBF and to the definition of the most appropriate processing conditions for them, independent of the specific AM machine applied.
Highlights
Powder bed fusion (PBF) is rapidly prevailing as the most important additive manufacturing (AM) technique to fabricate metal parts
In spite of the fast growth of laser-based powder bed fusion (L-PBF) processes as a part of everyday industrial practice, achieving consistent production is hampered by the scarce repeatability of performance that is often encountered across different additive manufacturing (AM) machines
This paper proposes a structured procedure with a complete test plan, which defines step-by-step the standardized actions that should be taken to optimize the processing parameters and scanning strategy in L-PBF of new alloy grades
Summary
Powder bed fusion (PBF) is rapidly prevailing as the most important additive manufacturing (AM) technique to fabricate metal parts. The drive to reach standard procedures is overwhelming whenever qualification of new materials and processing methods is involved [31,32] To this aim, for example, Portolés et al [33] contributed to establishing a qualification procedure to fabricate and repair aerospace parts produced by electron beam melting (EBM). As a first measure toward defining comprehensive quality assurance/quality control procedures, the methodology proposed by Portolés et al [33] accounts for all the parameters that are expected to affect both the technical requirements for finished parts and the process reproducibility by means of nine steps or “studies” that span from the validation of recycled powder to the surface finish of built parts. The main intention is to foster a constructive discussion in the literature, in order to support the progressive buildup of an established and commonly accepted procedure to optimize PBF process parameters
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