Powder Bed Research Articles

The Effect of Aging Heat Treatments on Room and High-Temperature Wear Performance of the Inconel 718™ Manufactured by Laser Powder Bed Fusion

The Effect of Aging Heat Treatments on Room and High-Temperature Wear Performance of the Inconel 718™ Manufactured by Laser Powder Bed Fusion

A study on the effect of print parameters on the internal structural quality of 316 L samples printed via laser powder bed fusion: Experimental and algorithmic approach

AbstractThis work aims to establish a quality assurance methodology for additively manufactured (AM) samples, produced from laser powder bed fusion (LPBF) method. The method incorporates resonance frequency method (RFM), where reference samples from wrought 316 L will be used to establish a data‐base with a set of reference frequencies. The data‐base is enhanced further with simulated frequencies, via FEM method, which was carried out on samples with the same dimensions and material properties as those of the reference. The quality of LPBF samples were benchmarked against this database. Four sets of LPBF samples (termed as A, B, C, and D) were printed with different parameters, and their densities were measured to understand deviations from the reference database. It was observed that Set‐C had the least drop in density of approx. 0.65% when compared to the wrought samples. Microscopic analysis revealed that the melt pools were clearly visible in all the samples, with no significant effect from different print parameters. Subsequently RFM was performed on all the sets and clear shifts in frequencies observed. Set‐C had the least deviation when compared to the reference (averaged at 200 Hz), whereas it was 250, 300, and 400 Hz for Set‐D, Set‐A and Set‐B respectively. There are several reasons for the frequency shift, the presence of porosity being one of them. Set‐B had the highest concentration of porosity in the ‐YZ plane. An algorithm was developed to sort the samples based on the frequency shifts seen from those of the samples from wrought 316 L. The sorting methodology was based on the shift frequencies, and the farther the sift is from the wrought the worst it get in terms of quality. The algorithm, which is programmed based on this methodology, was tested on a new set of LPBF samples and its effectiveness validated.

Fatigue Response of Additive-Manufactured 316L Stainless Steel

This study investigated the fatigue performance of 316L stainless steel fabricated via laser powder bed fusion (LPBF). Stress-controlled fatigue tests were performed at different stress amplitudes on vertically built samples using a frequency of 15 Hz and a stress ratio of 0.1. The stress amplitudes were varied to provide the cyclic response of the materials under a range of loading conditions. The average fatigue strength was determined to be 92.94 MPa, corresponding to a maximum stress of 185.87 MPa. The microstructures were observed through scanning electron microscopy (SEM) with the aid of electron backscattered diffraction (EBSD), and the average grain size of the as-built samples was determined to be 15.6 µm, with most grains having a <110> preferred crystallographic orientation. A higher kernel average misorientation value was measured on the deformed surfaces, revealing the increased misorientation of the grains. Defects were observed on the fractured surfaces acting as crack initiators while deflecting the crack propagation paths. The fatigue failure mode for the LPBF 316L samples was ductile, as illustrated by the numerous dimples on fracture surfaces and fatigue striations.

Spreading anomaly semantic segmentation and 3D reconstruction of binder jet additive manufacturing powder bed images

Variability in the inherently dynamic nature of additive manufacturing introduces imperfections that hinder the commercialization of new materials. Binder jetting produces ceramic and metallic parts, but low green densities and spreading anomalies reduce the predictability and processability of resulting geometries. In situ feedback presents a method for robust evaluation of spreading anomalies, reducing the number of required builds to refine processing parameters in a multivariate space. In this study, we report layer-wise powder bed semantic segmentation for the first time with a visually light ceramic powder, alumina, or Al2O3, leveraging an image analysis software to rapidly segment optical images acquired during the additive manufacturing process. Using preexisting image analysis tools allowed for rapid analysis of 316 stainless steel and alumina powders with small data sets by providing an accessible framework for implementing neural networks. Models trained on five build layers for each material to classify base powder, parts, streaking, short spreading, and bumps from recoater friction with testing categorical accuracies greater than 90%. Lower model performance accompanied the more subtle spreading features present in the white alumina compared to the darker steel. Applications of models to new builds demonstrated repeatability with the resulting models, and trends in classified pixels reflected corrections made to processing parameters. Through the development of robust analysis techniques and feedback for new materials, parameters can be corrected as builds progress.

Study on the Surface Quality of Overhanging Holes Fabricated by Additive/Subtractive Hybrid Manufacturing for Ti6Al4V Alloy

Additive/subtractive hybrid manufacturing (ASHM) based on laser powder bed fusion (LPBF) enables to achieve high precision and good surface quality of complex structures such as small holes with overhanging features. However, the rapid heating and cooling rates during the ASHM results in sinkage at the alternating interface of additive manufacturing and subtractive milling, which degrades the surface quality of the components. This study employs shielding height at the alternating interface to solve this problem and improve the surface quality. The effect of internal diameters and shielding heights on the surface quality were studied experimentally for overhanging holes fabricated by ASHM of Ti6Al4V. The results show that the Ti6Al4V samples prepared by LPBF possessed high density and uniformly distributed microstructure. For overhanging holes without shielding height, the largest depth value of sinkage and surface roughness were obtained, indicating a worse surface quality; when the shielding height was increased to 0.5 mm, the smallest sinkage value and surface roughness were obtained, indicating a better surface quality. With the same shielding height, the overhanging holes with different diameters had a similar surface roughness. This study reveals that an appropriate shielding height can improve the surface quality, which provides guidance to the improvement of the surface quality for complex structures in ASHM.

Correlation analysis of feedstock flowability and temperature for laser-based powder bed fusion of polymers

Purpose For additive manufacturing (AM) through laser-based powder bed fusion of polymers (PBF-LB/P), accurate characterization of powder flowability is vital for achieving high-quality parts. However, accurately characterizing feedstock flowability presents challenges because of a lack of consensus on which tests to perform and the diverse forces and mechanisms involved. This study aims to undertake a thorough investigation into the flowability of eight feedstock materials for PBF-LB/P at different temperatures using various techniques. Design/methodology/approach For ambient temperature assessments, established metrics such as avalanche angle and Hausner ratio, along with the approximated flow function coefficient (FFCapp), are used. The study then focuses on the influence of elevated temperatures representative of in-process conditions. FFCapp and differential scanning calorimetry (DSC) are performed and analyzed, followed by a correlation analysis as a holistic approach to identify key aspects for flowability. Furthermore, two feedstock materials are compared with a previous study to connect the present findings to PBF-LB/P processing. Findings The study revealed intrinsic material properties such as mechanical softening near the melting point to become significant. This partially explains why certain powders with poor ambient temperature flowability are consistently demonstrated to produce high-quality parts. FFCapp and thermal characterization through DSC are identified as critical metrics for optimizing feedstock material characteristics across temperature ranges. Originality/value Previous studies emphasized specific characterizations of feedstock material at ambient temperature, presented a limited materials selection or focused on metrics such as shape factors. In contrast, this study addresses a partially understood aspect by examining the critical role of temperature in governing feedstock material flowability. It advocates for the inclusion of temperature variables in flowability analyses to closely resemble the PBF-LB/P process, which can be applied to material design, selection and process optimization.

Targeted mechanical and energy absorption properties of 3D printed aluminium metamaterials

The potential of 3D-printed AlSi10Mg auxetic structures for diverse mechanical and energy-absorbing needs remains untapped. This article reveals a multi-criteria framework for the laser powder bed fused (L-PBF) −υ architecture considering elastic modulus (E), yield strength (σy), specific energy absorption (SEA), peak crush force (PCF) and crush force efficiency (CFE). The framework seamlessly combines trial data, multi-criteria decision-making, and performance indicators. Five auxetic structures were 3D-printed, characterised for mechanical and energy absorption traits within a 0.17–0.26 relative density range. The outcomes revealed a range of values for various parameters, including the Poisson’s ratio (−0.03 to −0.22), porosity (80.87–87.60 %), CFE (33–83 %), elastic modulus (100–632 MPa), yield strength (1.8–10 MPa), and SEA (0.5–6.8 kJ/kg). The reliability of these structures was ensured through a meticulous selection process based on an extensive literature review and empirical validation. To address the limitations of theoretical models, our work goes beyond theoretical predictions by experimentally validating these properties and integrating advanced methodologies such as the ‘analytic hierarchy process’ (AHP) and the ‘technique for order of preference by similarity to ideal solution’ (TOPSIS). This allows us to determine the best-performing auxetic architecture. The decision-making process was informed by five user-defined parameters prioritised in the order of CFE>−υ> E>σy> SEA based on their relative closeness identifying AUX5 as the best performing auxetic architecture. This study introduces an innovative method for crafting scenario-based auxetic architectures with varying performance levels based on their relative importance.

The defects and compressive behavior of NiTi alloy fabricated by laser powder bed fusion under a wide process space

A wide process space with laser power (P) of 50 ～ 400 W and scanning speed (s) of 50 ～ 2400 mm/s with the energy density (ED) range of 93–556 J/mm3 has been employed to fabricate NiTi alloy using laser powder bed fusion (LPBF). The optimal process window for near-full dense materials free of geometrical and metallurgical defects was determined. The characteristics of microstructures and compressive behaviors were comprehensively investigated. The results have shown that the process combinations of “high P + low s” and “high P + high s” are prone to bulging and warping defects due to rapid heating and cooling, respectively. A combination of “low P + low s” produces a relatively shallow melt pool without keyhole formation even at ED as high as 556 J/mm3. The austenite-martensite phase transition temperature (TTs) variations of ～80℃ were obtained with the process window free of porosity. The pre-existing martensite lath probably formed by plastic distortion (bulging) was responsible for the lowest critical stress of induced martensite (σSIM). The texture and nano-sized NiTi2/Ni2Ti4Ox precipitates also contribute to the variation of σSIM and residual strain among the samples with the same level of TTs upon compressive loading.

Ni4Ti3 precipitates formed in NiTi alloy modulated by powder bed fusion and their effects on mechanical and electrical deformation

In this study, NiTi alloys featuring different distributions and morphologies of Ni4Ti3 precipitates were developed via powder bed fusion (PBF) technology. The effects of these Ni4Ti3 precipitates on the mechanical, resistive, and electrical deformational properties of the alloys were also studied. With increasing laser energy density, a coarsening behavior of the semi-coherent Ni4Ti3 precipitates was observed, with these precipitates transitioning from needle-like to disk-like structures. Consequently, their coherence with the B2 matrix diminished, thus weakening the surrounding strain field. The presence of dislocations and uniformly dispersed Ni4Ti3 precipitates, endowed the NiTi alloy with enhanced resistivity (7.294 μΩ·m) and stable tensile recovery strain (2–4 %) during stress-controlled loading and unloading. Employing PBF, a NiTi spring actuator was produced, capable of lifting loads over 145 times its weight, with a shape-memory recovery efficiency of 76.80 % at a current of 3.0 A. This study demonstrated the versatility of PBF technology in tailoring the microstructure of NiTi alloys by adjusting the laser energy density, providing a laboratory reference for advanced applications in electrically induced deformation.

Interaction of contour and hatch parameters on vertical surface roughness in laser powder bed fusion

In Laser Powder Bed Fusion (L-PBF), surface roughness is pivotal for controlling the mechanical and functional performances, as well as the geometrical accuracy of the final product. This study extensively investigated the interactions of hatch and contour processing parameters, along with contour offset distance, on vertical surface roughness for 316L stainless steel in L-PBF. Melt pool morphology and surface arithmetic average roughness (Sa) were quantified using confocal microscopy, while scanning electron microscopy was employed to interpret the detailed microstructure of surface features. Under low volumetric energy density (VED) hatch conditions (e.g., 66.7 J/mm3), varying the contour offset distance has a negatable effect on the surface roughness when the contour VED is lower than 121.6 J/mm3, remaining relatively smooth surfaces dominated by bare melt tracks with sparely attached partially melted particles. Increasing the hatch or contour VED (e.g., 166.7 J/mm3), dross formation, identified by the microstructural differences and explained by the melt pool instability and migration, is inevitable, which dictates the surface roughness with higher Sa values. The larger contour offset distance further promotes the dross occurrence with irregularity and increases Sa. Employing a low contour VED with an appropriate offset distance and adopting the contour-first scan strategy was demonstrated as an effective solution to reduce the dross formation. Through the analysis of melt pool behavior, surface topography, and microstructure, this study elucidates the mechanisms governing dominant surface characteristics under the combined influence of hatch and contour parameters. It lays the foundation for precise control of surface roughness without altering hatching parameters, enabling the tailored manipulation of performance in additively manufactured structures.

Study on Crack Behavior of GH3230 Superalloy Fabricated via High-Throughput Additive Manufacturing.

This study utilized Fe, Co, Ni elemental powders alongside GH3230 pre-alloyed powder as raw materials, employing high-throughput additive manufacturing based on laser powder bed fusion in situ to alloying technology to fabricate the bulk samples library for GH3230 superalloy efficiently. A quantitative identification algorithm for detecting crack and hole defects in additive manufacturing samples was developed. The primary focus was to analyze the composition variations in specimens at varying Fe, Co, and Ni elemental compositions and their impact on crack formation. Experimental results demonstrated that increased laser power improved element distribution uniformity but it proved to be not significantly effective in reducing crack defects. Moreover, augmented Fe and Co alloying content could not eliminate these defects. However, elevated Ni content led to a decrease in the alloy's solidification cracking index and carbide reduction in solidification products. Notably, a significant reduction in cracks was observed when the Ni content of the alloy reached 63 wt.%, and these defects were nearly eliminated at 67 wt.% Ni content.

Thermal modeling of variable process parameter effects in powder bed fusion using electron beam

Purpose This study aims to develop a novel thermal modeling strategy to simulate electron beam powder bed fusion at part scale with machine-varying process parameters strategy. Single-bead and part-scale experiments and modeling were studied. Scanning strategies were described by the process controlling functions that enabled modeling. Design/methodology/approach The finite element analysis thermal model was used along with the powder bed fusion with electron beam experiments. The proposed strategy involves dividing a part into smaller sections and creating meso-scale models for each subsection. These meso-scale models take into consideration the variable process parameters, including power and velocity of the moving heat source, during part building. Subsequently, these models are integrated to perform partscale simulations, enabling more realistic predictions of thermal accumulation and resulting distortions. The model was built and validated with single-bead experiments and bulky parts with different features. Findings Single-bead experiments demonstrated an average error rate of 6%–24% for melt pool dimension prediction using the proposed meso-scale models with different scanning control functions. Part-scale simulations for three different geometries (cantilever beams with supports, bulk artifact and topology-optimized transfer arm) showed good agreement between modeled temperature changes and experimental deformation values. Originality/value This study presents a novel approach for electron beam powder bed fusion modeling that leverages meso-scale models to capture the influence of variable process parameters on part quality. This strategy offers improved accuracy for predicting part geometry and identifying potential defects, leading to a more efficient additive manufacturing process.

Additive Manufacturing of PH 13-8 Mo Family: A Review

The PH 13-8 Mo family of steels belong to the martensitic precipitation hardening stainless steels (MPHSSs) category, which exhibits a good combination of mechanical properties and corrosion resistance. Additive manufacturing (AM) offers advantages, including reduced material waste and the capability to produce complex, near-net-shape parts. Consequently, the application of AM techniques to the PH 13-8 Mo family is being increasingly explored across various industries. This review paper presents the existing literature on the topic and provides an overview. The review starts by presenting information about the PH 13-8 Mo family, including microstructure, chemical compositions, heat treatments, and mechanical properties. Afterwards, the work focuses on presenting the microstructure and resulting properties of PH 13-8 Mo family processed by three different additive manufacturing processes: Powder Bed Fusion using a Laser Beam (PBF-LB), Directed Energy Deposition using an Electric Arc (DED-Arc), and Directed Energy Deposition using a Laser Beam (DED-LB), both in their as-built condition and following post-processing heat treatments. The review concludes with a summary and outlook that highlights existing knowledge gaps and underscores the need for further research to tailor the microstructural evolution and enhance the properties. The findings indicate that AM of the PH 13-8 Mo family has the potential for industrial applications, yet further studies are necessary to optimize its performance.

Influence of Heat Treatment on Fretting Wear Behavior of Laser Powder Bed Fusion Inconel 718 Alloy

Abstract This research paper focuses on the fretting wear characteristics of self-mated laser powder bed fusion (L-PBF)-produced Inconel 718 alloy, with the primary aim of characterizing its distinct wear-rate in relation to fretting cycles. This study investigates both the as-built and heat-treated Inconel 718 Superalloy. Experiments were conducted under aggressive contact conditions, involving a flat-on-flat contact pressure of 100 MPa (1645 N) and a temperature of 650 °C sustained over a million cycles. From the preliminary observation, the microstructure reveals that the heat-treated L-PBF alloy has denser and harder precipitates than its as-built counterpart. This indicates that heat-treated alloy is much harder (470 HV0.3) than the as-built Inconel 718 (275 HV0.3). The heat treatment process resulted in the precipitation of beneficial strengthening phases like γ′ and γ″, along with maintaining stable carbides (NbC). Notably, the heat-treated material displays an approximately two-fold lower wear-rate (0.103 μm/cycle at the end of 1000 k cycles) compared to the as-built material (0.238 μm/cycle), attributed primarily to its high strength characteristics. Additionally, the heat-treated material demonstrates a reduced steady-state friction coefficient (0.34) in contrast to the as-built material (0.37), owing to its inherent capability to form a uniform and stable lubricious glaze oxide layer. Both as-built and heat-treated systems show dominant adhesive wear mechanisms along with localized abrasion resulting from the combination of oxidation and cyclic wear processes.

Effect of Direct Aging Heat Treatment on Microstructure and Mechanical Properties of Laser Powder Bed Fused Maraging Steel 300-Grade Alloy

Abstract This paper investigates the effects of a 6-hour direct aging heat treatment at 490 °C on the mechanical, tribological, and microstructure characteristics of laser powder bed fused maraging 300 steels, which is produced at various laser energy densities. After direct aging heat treatment, the grain boundaries become irregular and vague due to the residual stress releasing, squeezing of precipitates into the grain boundaries, and phase transformations. The XRD analysis reveals the reverted austenite (γ′) phase forms during aging treatment due to the inevitable reversion of metastable martensite to the stable reverted γ′ phase. The heat-treated samples' microhardness rises with rising the laser energy density (LED) from 61.41 to 92.10 J/mm3 due to a decrease in the reversed austenite phase and a further rise in LED decreases the microhardness of heat-treated samples due to a rise in the reversed austenite phase after heat treatment. The heat-treated sample produced at LED of 92.10 J/mm3 shows maximum yield, ultimate tensile strengths, and minimum elongation percentage due to its high microhardness, and the fractography results show the failure mode as a mixed brittle and ductile fracture. The wear-rate of the heat-treated additively manufactured maraging 300 steel decreases as the LED increases from 61.41 to 92.1 J/mm3 and a further rise in LED from 92.10 J/mm3 to 166.66 J/mm3, the wear-rate increases. The wear-rate rises with a rise in sliding velocity from 1.5–3.5 m/s. The dominant wear mechanism was observed as abrasion with small grooves and saplings.

Surface roughness reduction in electron beam powder bed fusion additive manufacturing of super duplex stainless steel 2507: investigating optimisation techniques and face orientation-dependent irregularities

AbstractThe use of additive manufacturing in metals by powder bed fusion via electron beam (PBF-EB) is increasing for fabricating high-quality parts meeting industrial standards. However, high surface roughness poses a consistent challenge in PBF-EB. This study investigates two novel approaches to optimise surface roughness for a given machine and powder combination. Using machine control software’s recently introduced research mode functionality, we develop customised beam control code to effectively explore a vast parameter space. Additionally, we explored the impact of beam travel direction and spot morphology on surface roughness. Line-melt-based contours were explored by specimen manufacturing with layer-wise parameter change, whilst spot-melting-based samples were built using a full factorial design of experiments with four factors at three levels. Initial sample characterisation was done using a stylus-based contact profilometer, followed by detailed evaluation using focus variation microscopy. Results reveal that increasing beam power and spot energy exacerbate surface roughness. We also find that a well-defined energy distribution at the spot's edge contributes to smoother surfaces. Whilst the influence of beam travel direction on surface roughness remains uncertain, our findings underscore the importance of parameter selection in achieving optimal results. By adjusting contouring parameters, we achieve a vertical roughness of Ra17.7 ± 0.9 (Sa 21.6), significantly lower than in the current literature. These findings advance our understanding of surface roughness optimisation in PBF-EB and offer practical insights for improving part quality in industrial applications. By harnessing tailored beam control strategies, manufacturers can enhance the capabilities of additive manufacturing technologies in producing metal components.

High-Cycle Fatigue Performance of Laser Powder Bed Fusion Ti-6Al-4V Alloy with Inherent Internal Defects: A Critical Literature Review

The inadequate fatigue performance of Laser Powder Bed Fusion (L-PBF) Ti-6Al-4V alloy, primarily due to intrinsic defects, poses a significant challenge for industrial applications. Internal defects often serve as initiation sites for fatigue cracks, significantly impacting the fatigue life of L-PBF Ti-6Al-4V components. Accurate evaluation of the role of internal defects in fatigue performance and quantitative analysis of influential parameters are crucial for guiding optimal L-PBF manufacturing design. This study aims to critically review recent notable contributions focusing on high-cycle fatigue (HCF) in these alloys, with many of the presented insights being easily transferred to other types of AM alloys. Efforts have been made to identify correlations between fatigue life at various stages and critical internal defects. Key aspects, including microstructure and post-processing treatments, and their effects on HCF have been thoroughly analyzed. The findings enhance the scientific understanding of fatigue performance of L-PBF Ti-6Al-4V alloy and open new avenues for future research.

Effect of laser speed on neck formation in SS316L powder joining for LPBF

The objective of this study is to comprehend how changes in laser speed affect the behaviour and features of neck formation in SS316L during powder bed fusion. This study examines the impact of various laser speeds on the neck formation in the commonly used SS316L. Uniweld Laser 3000 was used for laser joining. A constant laser power of 15 W and laser scan speed of 25–150 mm/s were implemented, and powder joining within a single track was observed. Results show that neck size decreases with increasing laser scanning speed and no particle joining occurs at 150 mm/s scan speed, as it is considered too fast for sufficient heat absorption and melting. As laser speed decreases to 125 mm/s, neck starts to form because the particles absorb more heat, which facilitates melting and bonding. Surface diffusion occurs early at this stage because it requires only a small amount of energy to break atomic bonds on the surfaces of particles compared to those in the internal part. This process involves atoms moving along the surfaces of the particles, facilitating the initial stages of sintering by reducing surface energy and causing neck formation between particles. At 125 mm/s, the particle shape remains spherical, and the average neck size is 49 μm. At 100 μm, the powder average neck size is 62 μm. Moreover, the powder completely merges at 50 mm/s and 25 mm/s. The neck formed between particles considerably improves the product's mechanical strength by strengthening bonds between particles. Material density increases with neck quality, and stable neck growth can reduce the porosity of the final parts. Ensuring thermal stability in the laser powder bed fusion allows consistent heat to particles, ensuring even temperature in materials and ultimately facilitating stable neck growth. Thermal stability enables atoms in particles to migrate efficiently and prevents defects, such as bubbling, which increases porosity in printed parts. Therefore, a slow scanning speed allows particles to absorb more heat for melting, increasing the neck size of particles. This knowledge is useful for optimizing laser processing parameters in various industrial applications.

Effect of pre-heat temperature on enhancing the processability of pure zinc by laser-based powder bed fusion

Effect of pre-heat temperature on enhancing the processability of pure zinc by laser-based powder bed fusion

Orthogonal experimental method to investigate the effect of process parameters on the mechanical properties of thin-walled parts by PBF-LB/M

Lightweight thin-walled parts are widely used in the aviation and aerospace industries, and with the further increase in the complexity of their features, the traditional manufacturing process can no longer fully meet the high requirements of industrial component manufacturing. In this work, thin-walled parts are processed by Laser based powder bed fusion of metals (PBF-LB/M), and the effects of process parameters on residual stress, hardness, mechanical properties and microstructure of thin-walled parts are systematically investigated. The simulation results show that the maximum equivalent residual stresses are distributed in the combination of the solid and the substrate, and the minimum equivalent residual stresses are mainly distributed in the top two ends and the middle part of the solid, and the stress distribution is symmetrical. In addition, the maximum equivalent residual stress increases with the increase of laser power, and decreases with the increase of scanning spacing or scanning speed. The experimental results show that with the increase of laser energy density, the tensile strength and yield strength of thin-walled parts show a tendency of increasing first and then decreasing. Finally, high-quality thin-walled parts were successfully fabricated by the optimized process parameters, and their tensile and yield strengths were increased by 6.1% and 15.9%, respectively.