Abstract
Featured Application This article provides proper fitting parameters, for a wide variety of metallic alloys, to apply the derived mathematical expression (which allows to determine the scanning speed value needed, with respect to laser power) to produce highly dense components through selective laser melting. In this work, a previously developed mathematical model to predict bulk density of SLMed (produced via Selective Laser Melting) component is enhanced by taking laser power, scanning speed, hatch spacing, powder’s thermal conductivity and specific heat capacity as independent variables. Experimental data and manufacturing conditions for the selective laser melting (SLM) of metallic materials (which include aluminum, steel, titanium, copper, tungsten and nickel alloys) are adapted from the literature and used to evaluate the validity of the proposed enhanced model. A strong relation between dependent and independent dimensionless products is observed throughout the studied materials. The proposed enhanced mathematical model shows to be highly accurate since the computed root-mean-square-error values (RMSE) does not exceed 5 × 10−7. Furthermore, an analytical expression for the prediction of bulk density of SLMed components was developed. From this, an expression for determining the needed scanning speed, with respect to laser power, to achieve highly dense components produced via SLM, is derived.
Highlights
From dimensional analysis we were able to obtain two relevant findings: (1) a mathematical expression to predict the bulk density of components produced through selective laser melting and (2) a mathematical expression for the calculation of the required scanning speed, with respect to laser power, to attain metallic pieces of low porosity
The dimensional analysis provided an insight on the interaction of manufacturing parameters and physical properties involved in the Selective laser melting (SLM) process
From Equation (6), we could conclude that the bulk density of an additive manufacturing (AM) component produced via SLM will be positively influenced by laser power supply, and inversely by scanning speed and hatch distance
Summary
Publisher’s Note: MDPI stays neutral with regard to jurisdictional claims in published maps and institutional affiliations. Selective laser melting (SLM) is an additive manufacturing (AM) process that produces geometrically complex components from metallic powders. It uses a high intensity laser, in an inert atmosphere, to selectively melt specific regions of prelaid powder. The material quickly melts, cools and solidifies. The final component is built layer-by-layer in an iterative process of powder spreading from a feed container, scanning of the laser and lowering of the build platform [1,2,3,4]
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