Abstract
The spreading powder layer plays a vital role in determining the quality of Laser powder bed fusion (LPBF) -manufactured samples. In this study, the effect of layer thickness is investigated numerically and experimentally. It was determined that the void fraction at a certain height is higher than that of the entire layer, especially for thicker layers, because of gravity. The former is consistent with the experimental result for powders of the same thickness. The void fraction of the sintered part was also measured to confirm their relationship. Furthermore, the dynamics of spreading particles on a particle bed were numerically studied to investigate whether support powders around the sintered part affect the powder-spreading process. The powder layer on a particle bed is denser than that on an adjacent solid bed, suggesting that support powders will affect the powder-spreading of the sintered part, especially its borders, and contribute to the surface topography.
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