Abstract
Powder Bed Selective Laser Processing (PBSLP) is a promising technique for the additive manufacturing of alumina. For the method’s success, PBSLP process parameters such as laser power, scanning speed, hatching distance, and scanning strategies need to be investigated. This paper focuses on studying the scanning strategies’ effects on the PBSLP of alumina numerically and experimentally. Scanning strategies such as linear with different orientation, concentric, and islands were investigated. A numerical model was developed in which the PBSLP parameters, scanning strategy effects, and interpreting the experimental results could be observed. The numerical model proved its ability to reach the proper process parameters instead of using experimental trails which are time and cost consuming. For relative density, the island strategy succeeded to print alumina samples with a high relative density reaching 87.8%. However, there are round passages formed inside the samples that remain a barrier for the island strategy to be effectively used in PBSLP of alumina. Both linear and concentric strategies achieved a relative density of 75% and 67%, respectively. Considering the top surface roughness, samples printed with linear strategies gave low top surface roughness compared to the island and concentric strategies. Linear-45° is considered the effective strategy among the studied strategies as it achieved good relative density and low roughness at top and side surfaces. For PBSLP of alumina, new scanning strategies should be considered, and this study presents a new scanning strategy that is mainly based on space filling mathematical curves and should be studied in future work.
Highlights
Accepted: 7 January 2022Aluminum oxide, characterized by its unique physical and mechanical properties, is one of the most important ceramic materials [1]
It has been concluded from reviewing the literature about Powder Bed Selective Laser Processing (PBSLP) of alumina that the focus is limited, and there is a real need to investigate it deeply, especially the process parameters
The Laser Beam-Powder Bed Fusion (LB-PBF) 125 printer manufactured by RENISHAW® and equipped with fiber laser was used to print the alumina samples
Summary
Aluminum oxide (alumina), characterized by its unique physical and mechanical properties, is one of the most important ceramic materials [1]. Studies analytical methods were used determine the initial values oflaser the process and have investigated the to process parameters, especially powerparameters and scanning to analyze the process numerically to reduce the time spent on practical studies [27,29,30] It has been concluded from reviewing the literature about PBSLP of alumina that the focus is limited, and there is a real need to investigate it deeply, especially the process parameters. Simulation and analytical methods were used to determine the initial values of the process parameters and to analyze the process numerically to reduce the time spent on practical studies [27,29,30]
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