Laser-based Additive Manufacturing Research Articles

Effects of Selective Laser Melting Process Parameters on Structural, Mechanical, Tribological and Corrosion Properties of CoCrFeMnNi High Entropy Alloy

AbstractThe structural, tribological, mechanical, corrosion, and other properties of materials produced by laser-based powder bed fusion additive manufacturing methods are significantly affected by production parameters and strategies. Therefore, understanding and controlling the effects of the parameters used in the manufacturing process on the material properties is extremely important for determining optimum production conditions and for saving time and materials. This study aimed to determine the optimal laser parameter values for CoCrFeMnNi high-entropy alloy powders using the selective laser melting (SLM) method. The layer thickness was kept constant during experimentation. 5 different laser powers and 10 varying laser scanning speeds were tested, with hatch spacing from 30 to 90%. After determining the optimal laser parameters for SLM, prismatic samples were fabricated in different build orientations (0°, 45°, and 90°), and subsequently, their structural, mechanical, tribological, and corrosion properties were compared. Melt pool morphology could not be obtained at 20—40 and 60W laser powers and at all laser scanning speeds used at these laser powers. At 100 W laser power, 600 mm/s laser scanning speed, and 70% hatch spacing parameters, an ultimate tensile stress of 550 MPa and elongation of 48% were obtained. Among the samples produced in different build orientations, the sample produced with a 0° build orientation exhibited the highest relative density (99.94%), the highest microhardness (201.2 HV0.1), the lowest friction coefficient (0.7025), and the lowest wear and corrosion rates (0.7875 mpy). Additionally, SLM parameters were evaluated to have a significant impact on the performance of all properties of the samples. Graphical Abstract

Size matters: Exploring part size effects on microstructure, defects, and mechanical property in optimized laser powder bed fusion (L-PBF) additive manufacturing

In laser-based metal additive manufacturing (MAM), effective process optimization requires a thorough analysis of variations across the process window. Despite the common practice of utilizing small-sized coupons to optimize process parameters in laser-based MAM, this study challenges this convention. Through an analysis of microstructure and defect differences in Fe-Ni material parts produced via laser-powder bed fusion (L-PBF), the study reveals significant discrepancies in microstructure, defect and mechanical property based on part size. As part size increases, lack-of-fusion defects and cracks become more pronounced, resulting in a decrease in density from 8.11 g/cm3 to 8.02 g/cm3, leading to constrained grain growth with a decrease of grain size from 41.88 μm to 23.07 μm in the scanning plane. Each defect and microstructural difference was traced back to variations in thermal history based on part size. Finite element method simulations, highlighting differences in thermal history from scanning a single layer to the entire part, showed that an increase in scan length with a widened scan area enlarged the period of the thermal history cycle, leading to considerable cooling. This study underscores crucial considerations for future researchers engaged in process optimization for novel alloy systems using laser-based MAM processes.

Microstructural evolution and tensile properties of direct energy deposited Ti-4Al-5Co-0.25Si alloy during heat treatment

Additive manufacturing (AM) stands as an advanced manufacturing process, successfully utilized for the fabrication of high-value titanium components. However, these components have yet to find widespread use in industrial applications due to their inadequate performance when compared to conventionally processed parts. Consequently, there is a pressing demand to develop new alloys and microstructural control strategies to overcome this limitation. Here, we have designed a cost-effective Ti-4Al-5Co-0.25Si alloy for use in laser-based direct energy deposition additive manufacturing. The selection of solute elements has resulted in both solute strengthening and grain refinement. Additionally, the implementation of a heat-treatment schedule has allowed for control over the phase constituents and their stability. The as-fabricated alloy exhibits a prior-β grain size of ∼50 μm, α plate thickness of ∼0.6 μm, and tensile strength of 1145 MPa. Subsequent heat treatment induces the formation of subgrains, discontinuous grain boundary α and metastable β phases, and ultrafine martensitic features ranging from 40 to 100 nm. Moreover, this heat treatment improved the tensile strength of the alloy to 1500 MPa while maintaining an elongation of ∼5%. Importantly, the proposed hierarchical structured alloy offers an economical alternative, outperforming commercially available titanium alloys. This study presents a new direction for further research into alloy and microstructural design, aiming at the development of low-cost, high-performance titanium alloys suitable for additive manufacturing.

Influence of heat treatments on low-power-LPBFed CuCrZr for nuclear fusion applications

In this study, the processability of CuCrZr alloy with additive manufacturing (AM) technology and the performance achievable with Direct Age Hardening treatments for nuclear fusion applications were investigated. This copper alloy is one of the most interesting for the field: it is easier to manufacture through Laser-based additive manufacturing technology and mechanically superior compared to pure copper, and it ensures values of thermal conductivity high enough to be considered a valid substitute for pure copper in many applications.The investigation on CuCrZr alloy was carried out in order to examine the influence of Direct Age Hardening (DAH) treatments on physical and mechanical properties. Laser Powder Bed Fusion technology was used to produce samples with CuCrZr alloy. The additive manufacturing process involved a machine provided with a 370 W IR laser and a preliminary process optimization was carried out to find the printing parameters that assured the highest density (99.15 %), which confirmed the processability of CuCrZr alloy also with low IR laser power. Then, three different DAH treatments were tested and the performance of DAHed material was compared to that of the alloy in as-built conditions. Precipitation phenomena were investigated with DSC analyses, revealing the effectiveness of the treatment already after 1 h. A deep microstructural investigation revealed a fine cellular structure formed during solidification and the presence of nanometric precipitates starting from the as-built condition. The presence of microstructural defects was also investigated. Mechanical performance and thermal conductivity were tested, too: the as-built samples showed limited properties, while very promising results for the use of additively manufactured CuCrZr components have been obtained after the DAHs. The ultimate tensile strength (UTS) and yield strength (YS) doubled the as-built values after 1 h treatment at 550 °C. The thermal conductivity reached three times the initial condition (from 100 W/mK to 300 W/mK).

Cold metal transfer-based wire arc additive manufacturing of pure copper with ultra high tensile strength

Copper is used in various heating and cooling applications by exploiting its excellent thermal and electrical conductivities. Powder- and laser-based additive manufacturing (AM) of pure copper is challenging as it encounters porosity because of its low absorptivity. The present research reports the feasibility of cold metal transfer-based wire arc additive manufacturing (CMT-WAAM) for the manufacturing of pure copper thin wall. The microstructure of the deposit is examined at three distinct locations. The mechanical properties (including ultimate tensile strength, yield strength, elongation and hardness) are examined in both scanning direction (SD) and build direction (BD). The thermal and electrical properties of the deposit are also measured. The deposited thin wall is reported to be firm and straight without any bulging and collapsing. The CMT-WAAM fabricated pure Cu samples exhibit superior tensile strength (310 ± 12 MPa in SD and 265 ± 9 in BD) than all other AM techniques. The thermal and electrical conductivities of the built copper wall are comparable to the previously reported conductivities of pure copper fabricated by other AM routes.

A hybrid CAD/CAE/CAM project‐based laboratory framework integrating topology optimization and laser powder bed fusion for engineering education

AbstractIn the era of Industry 4.0, laser‐based additive manufacturing (LBAM) has gained substantial momentum in the production of complex lightweight structures in several domains such as aerospace, civil, and biomedical engineering. The increasing demand for consistent and precise manufacturing processes has urged the manufacturing industry to consider the coupling of topology optimization (TO) and laser powder bed fusion (LPBF) in the design of sophisticatedly novel topologies that are unattainable through traditional processes. Notably, this union has demonstrated a highly efficient and productive capability toward the manufacturing industry. In line with this accelerated pace, engineering programs within universities exert significant effort to revise and update their engineering curriculum design to incorporate emerging manufacturing technologies providing students with skills that are aligned with the actual industrial context. In this article, a computer‐aided design (CAD)/computer‐aided engineering (CAE)/computer‐aided manufacturing (CAM) project‐based laboratory framework is proposed combining TO and LPBF exploiting a simulation‐based environment integrating CAD, CAE, and CAM. The structure of the proposed CAD/CAE/CAM design methodology is revisited to discern the added value of the newly developed framework and its particularity in assisting aerospace engineering students to meet industrial expectations. A new CAD/CAE/CAM project‐based laboratory framework has been developed integrating TO and LPBF using advanced engineering tools within the aerospace engineering education.

GENETIC ALGORITHM-BASED OPTIMIZATION OF THE LASER-BEAM PATH IN ADDITIVE MANUFACTURING

This study presents a methodology of genetic-algorithm-based optimization of the laser-beam path for improving laser-based additive manufacturing (AM). A simple thermal model was developed to simulate the effects of laser-induced heat input on the temperature distribution within the substrate during the fabrication of one layer. The optimization approach aims to find solutions with more homogeneous temperature properties that minimize the thermal gradient on the substrate caused by laser-based AM. The laser beam, i.e., the tool-path planning, is formulated as the search for the optimal sequence of cell depositions that minimize the fitness function, which is composed of two components, i.e., the thermal fitness and process fitness. The thermal fitness is expressed as the average thermal gradient, and the process fitness regulates the suitability of the proposed tool path for the implementation of the AM process. Various tool-path generators are proposed to initialize the initial population of tool-path solutions. Genetic-algorithm-based tool-path optimization is proposed, where custom initialization, crossover and mutation operators are developed for application in laser-based AM. Simulation studies demonstrate the effectiveness of the genetic-algorithm-based optimization in finding solutions that minimize the fitness function and therefore provide both thermally and, for the AM process implementation, more suitable laser-beam-path solutions.

Genetic Algorithm-Based Framework for Optimization of Laser Beam Path in Additive Manufacturing

In this study, a genetic algorithm-based laser beam (LB) path optimization method is presented to improve laser-based additive manufacturing (LBAM). To emulate the LBAM process, LB irradiation of a thin metal substrate is applied. The LB path generation is formulated as the search for the optimal sequence of LB irradiation into the cells on the substrate that minimizes the fitness function, which is composed of two components, i.e., thermal fitness and process fitness. The thermal fitness is expressed by the average thermal gradient, and a simple thermal model is developed to simulate the effects of laser-induced heat input on the temperature distribution in the substrate. The process fitness regulates the suitability of the proposed LB path for the implementation of the LBAM process. In addition to standardized tool paths (i.e., raster, spiral, etc.), novel LB path generators are proposed to define the initial population of LB path solutions. To implement a genetic algorithm-based LB path optimization, a framework is proposed, and custom initialization, crossover, and mutation operators are developed for application in LBAM. The effectiveness of the proposed approach is demonstrated through a simulation case study aiming to identify LB paths that minimize the fitness function and thus provide more suitable LB path solutions with respect to the defined fitness function. Compared with the traditional trial-and-error LB path formulations, the proposed approach provides an improved and automated method for an efficient laser beam path selection in LBAM.

Understanding the role of laser processing parameters and position-dependent heterogeneous elastocaloric effect in laser powder bed fused NiTi thin-walled structures

To reduce the driving load and enhance the heat exchange capacity and elastocaloric refrigeration efficiency, increasing interests in porous structure design and laser-based additive manufacturing (LAM) of NiTi materials with a large specific surface area have been emerging. As a type of characteristic unit of porous components, we mainly focused on the LAM process optimization and elastocaloric effect of NiTi-based thin-walled structures (TWSs) in this work. Firstly, we systemically studied the influence of laser processing parameter on the forming quality and phase transformation behavior of NiTi-based TWS samples. Results showed that high relative density (>99.0%) was inclined to be obtained in a range of 67–133 J mm−3 (laser energy density). Besides, the transformation temperatures (TTs) and enthalpy change roughly showed a positive linear relationship with the applied laser energy density. At an optimized parameter (P = 100 W and v = 1000 mm s−1), the sample exhibited a high relative density (99.88%), good dimensional accuracy, and the lowest TTs. Then, this work emphatically unveiled the position-dependence of phase transformation behavior and elastocaloric effect (eCE) in a NiTi-based TWS sample. It was found that both the TTs and enthalpy change monotonously decreased along the building direction, while the transformation strain kept an increase trend. As a result, the middle portion of the sample exhibited the largest adiabatic temperature change which reached 6.5 K at the applied stain of 4%. The variation in TTs and eCE could be attributed to the heterogeneous solidification microstructure induced by the thermal cycle nature of LAM process.

Experimental quantification of inward Marangoni convection and its impact on keyhole threshold in laser powder bed fusion of stainless steel

Laser metal additive manufacturing has the potential to revolutionize the production of complex geometries with high precision across various industrial applications. To optimize the reliability of the process, a detailed understanding of the melt pool dynamics during the process is essential, particularly in the nearly pore-free regimes. In this study, the melt pool dynamics across conduction mode to keyhole mode in laser powder bed fusion processing of stainless steel 316 L have been investigated by means of in-situ synchrotron X-ray imaging utilizing tungsten particles as tracers. The spatial distribution of the fluid flow in the melt pool has been quantified with a resolution of ∼10 µm through automatic tracing all moving particles in the melt pool. The results identified the influence of the interplay between laser power and scanning speed on melt flow velocities. The measurements also revealed a pronounced impact of the inward Marangoni convection on the conduction-keyhole threshold, offering a new degree of freedom to broaden the pore-free process window of laser-based additive manufacturing. These findings contribute to a more comprehensive understanding of the melt pool dynamics during laser metal additive manufacturing and provide a valuable reference for calibrating high-fidelity computational fluid dynamics models.

Study on Laser Polishing of Ti6Al4V Fabricated by Selective Laser Melting.

Laser-based additive manufacturing has garnered significant attention in recent years as a promising 3D-printing method for fabricating metallic components. However, the surface roughness of additive manufactured components has been considered a challenge to achieving high performance. At present, the average surface roughness (Sa) of AM parts can reach high levels, greater than 50 μm, and a maximum distance between the high peaks and the low valleys of more than 300 μm, which requires post machining. Therefore, laser polishing is increasingly being utilized as a method of surface treatment for metal alloys, wherein the rapid remelting and resolidification during the process significantly alter both the surface quality and subsurface material properties. In this paper, the surface roughness, microstructures, microhardness, and wear resistance of the as-received, continuous wave laser polishing (CWLP), and pulsed laser polishing (PLP) processed samples were investigated systematically. The results revealed that the surface roughness (Sa) of the as-received sample was 6.29 μm, which was reduced to 0.94 μm and 0.84 μm by CWLP and PLP processing, respectively. It was also found that a hardened layer, about 200 μm, was produced on the Ti6Al4V alloy surface after laser polishing, which can improve the mechanical properties of the component. The microhardness of the laser-polished samples was increased to about 482 HV with an improvement of about 25.2% compared with the as-received Ti6Al4V alloy. Moreover, the coefficient of friction (COF) was slightly reduced by both CWLP and LPL processing, and the wear rate of the surface layer was improved to 0.790 mm3/(N∙m) and 0.714 mm3/(N∙m), respectively, under dry fraction conditions.

Manipulating ionic conductivity through chemical modifications in solid-state electrolytes prepared with binderless laser powder bed fusion processing

Additive manufacturing of solid-state batteries is advantageous for improving the power density by increasing the geometric complexity of battery components, such as electrodes and electrolytes. In the present study, bulk three-dimensional Li1+x Al x Ti2−x (PO4)3 (LATP) electrolyte samples were prepared using the laser powder bed fusion (L-PBF) additive manufacturing method. Li3PO4 (LPO) was added to LATP to compensate for lithium vaporization during processing. Chemical compositions included 0, 1, 3, and 5 wt. % LPO. Resulting ionic conductivity values ranged from 1.4 × 10−6–6.4 × 10−8 S cm−1, with the highest value for the sample with a chemical composition of 3 wt. % LPO. Microstructural features were carefully measured for each chemical composition and correlated with each other and with ionic conductivity. These features and their corresponding ranges include: porosity (ranging from 5% to 19%), crack density (0.09–0.15 mm mm−2), concentration of residual LPO (0%–16%), and concentration and Feret diameter of secondary phases, AlPO4 (11%–18%, 0.40–0.61 µm) and TiO2 (9%–11%, 0.50–0.78). Correlations between the microstructural features and ionic conductivity ranged from −0.88 to 0.99. The strongest negative correlation was between crack density and ionic conductivity (−0.88), confirming the important role that processing defects play in limiting the performance of bulk solid-state electrolytes. The strongest positive correlation was between the concentration of AlPO4 and ionic conductivity (0.99), which is attributed to AlPO4 acting as a sintering aid and the role it plays in reducing the crack density. Our results indicate that additions of LPO can be used to balance competing microstructural features to design bulk three-dimensional LATP samples with improved ionic conductivity. As such, refinement of the chemical composition offers a promising approach to improving the processability and performance of functional ceramics prepared using binderless, laser-based additive manufacturing for solid-state battery applications.

Effects of Oxidized Metal Powders on Pore Defects in Powder-Fed Direct Energy Deposition.

Laser-based additive manufacturing processes, particularly direct energy deposition (DED), have gained prominence for fabricating complex, functionally graded, or customized parts. DED employs a high-powered heat source to melt metallic powder or wire, enabling precise control of grain structures and the production of high-strength objects. However, common defects, such as a lack of fusion and pores between layers or beads, can compromise the mechanical properties of the printed components. This study focuses on investigating the recurrent causes of pore defects in the powder-fed DED process, with a specific emphasis on the influence of oxidized metal powders. This research explores the impact of intentionally oxidizing metal powders of hot work tool steel H13 by exposing them to regulated humidity and temperature conditions. Scanning electron microscopy images and energy-dispersive X-ray spectroscopy results demonstrate the clumping of powders and the deposition of iron oxides in the oxidized powders at elevated temperatures (70 °C for 72 h). Multi-layered depositions of the oxidized H13 powders on STD61 substrate do not show significant differences in cross sections among specimens, suggesting that oxidation does not visibly form large pores. However, fine pores, detected through CT scanning, are observed in depositions of oxidized powders at higher temperatures. These fine pores, typically less than 250 µm in diameter, are irregularly distributed throughout the deposition, indicating a potential degradation in mechanical properties. The findings highlight the need for careful consideration of oxidation effects in optimizing process parameters for enhanced additive manufacturing quality.

A Computational Evaluation of Minimum Feature Size in Projection Two-Photon Lithography for Rapid Sub-100 nm Additive Manufacturing.

Two-photon lithography (TPL) is a laser-based additive manufacturing technique that enables the printing of arbitrarily complex cm-scale polymeric 3D structures with sub-micron features. Although various approaches have been investigated to enable the printing of fine features in TPL, it is still challenging to achieve rapid sub-100 nm 3D printing. A key limitation is that the physical phenomena that govern the theoretical and practical limits of the minimum feature size are not well known. Here, we investigate these limits in the projection TPL (P-PTL) process, which is a high-throughput variant of TPL, wherein entire 2D layers are printed at once. We quantify the effects of the projected feature size, optical power, exposure time, and photoinitiator concentration on the printed feature size through finite element modeling of photopolymerization. Simulations are performed rapidly over a vast parameter set exceeding 10,000 combinations through a dynamic programming scheme, which is implemented on high-performance computing resources. We demonstrate that there is no physics-based limit to the minimum feature sizes achievable with a precise and well-calibrated P-TPL system, despite the discrete nature of illumination. However, the practically achievable minimum feature size is limited by the increased sensitivity of the degree of polymer conversion to the processing parameters in the sub-100 nm regime. The insights generated here can serve as a roadmap towards fast, precise, and predictable sub-100 nm 3D printing.

Monitoring of laser-induced fast recrystallization in SS-316L through synchrotron X-ray diffraction

Laser based heat treatments have multiple applications for local tuning of microstructures. They are particularly relevant in the context of laser-based additive manufacturing (LAM), in order to relieve residual stresses or introduce equiaxed structures through recrystallization. In 316L, high stored energy inherited from the high cooling rates of laser processing creates strong crystallographic textures and stable cellular walls, which challenges the possibility of inducing fast recrystallization. In a first step, we perform here a laser heat treatment on a highly deformed 316L steel, and show that in-situ X-ray Diffraction (XRD) is a viable tool for the monitoring of fast recrystallization. The evolution of Bragg peak width over time is connected to the evolution of dislocation density and grain size, thanks to Electron Back-Scattered Diffraction (EBSD) and Transmission Electron Microscopy (TEM) characterization. X-ray signals are shown to reveal different stages of recrystallization, in particular the development of dislocation cells and the onset of nucleation. This study also demonstrates how local heat sources such as lasers may help designing composite-like materials for grain size, texture and hardness optimization.

A fundamental study of physical mechanisms of wineglass-shaped fusion zone profile in laser melting

The fusion zone geometry in laser melting processes e.g., laser welding and laser-based additive manufacturing, of metallic materials has commonly a wineglass-shaped profile which is critical to the grain orientation and stress distribution. Hereby, we adopt for the first time a decoupling work through a combination of multi-physics modelling and experiments to reveal the fundamental mechanisms of this special morphology. Two physics-based easy-to-use metal vapour models are proposed to consider the vapour's momentum and thermal effects separately. It is found that the direct laser energy absorption and Marangoni shear stress which are widely hypothesised to dominate the wineglass-shape formation show only a minor influence. The additional heating from the metallic vapour plume rather than its momentum impact contributes predominantly to the enlarging of the molten pool top region, resulting directly in the formation of the wineglass-shaped fusion zone. The generality of the plume heating effect is also validated in two types of materials (steel and Al) in a wide range of parameters.

Printed layers height calibration curve and porosity in laser melting deposition of Ti6Al4V combining experiments, mathematical modelling and deep neural network

PurposePorosity is a commonly analyzed defect in the laser-based additive manufacturing processes owing to the enormous thermal gradient caused by repeated melting and solidification. Currently, the porosity estimation is limited to powder bed fusion. The porosity estimation needs to be explored in the laser melting deposition (LMD) process, particularly analytical models that provide cost- and time-effective solutions compared to finite element analysis. For this purpose, this study aims to formulate two mathematical models for deposited layer dimensions and corresponding porosity in the LMD process.Design/methodology/approachIn this study, analytical models have been proposed. Initially, deposited layer dimensions, including layer height, width and depth, were calculated based on the operating parameters. These outputs were introduced in the second model to estimate the part porosity. The models were validated with experimental data for Ti6Al4V depositions on Ti6Al4V substrate. A calibration curve (CC) was also developed for Ti6Al4V material and characterized using X-ray computed tomography. The models were also validated with the experimental results adopted from literature. The validated models were linked with the deep neural network (DNN) for its training and testing using a total of 6,703 computations with 1,500 iterations. Here, laser power, laser scanning speed and powder feeding rate were selected inputs, whereas porosity was set as an output.FindingsThe computations indicate that owing to the simultaneous inclusion of powder particulates, the powder elements use a substantial percentage of the laser beam energy for their melting, resulting in laser beam energy attenuation and reducing thermal value at the substrate. The primary operating parameters are directly correlated with the number of layers and total height in CC. Through X-ray computed tomography analyses, the number of layers showed a straightforward correlation with mean sphericity, while a converse relation was identified with the number, mean volume and mean diameter of pores. DNN and analytical models showed 2%–3% and 7%–9% mean absolute deviations, respectively, compared to the experimental results.Originality/valueThis research provides a unique solution for LMD porosity estimation by linking the developed analytical computational models with artificial neural networking. The presented framework predicts the porosity in the LMD-ed parts efficiently.

Fast-throughput simulations of laser-based additive manufacturing in metals to study the influence of processing parameters on mechanical properties

Laser-powder bed fusion additive manufacturing (LPBF-AM) of metals is rapidly becoming one of the most important materials processing pathways for next-generation metallic parts and components in a number of important applications. However, the large parametric space that characterizes laser-based LPBF-AM makes it challenging to understand what are the variables controlling the microstructural and mechanical property outcomes. Sensitivity studies based on direct LPBF-AM processing are costly and lengthy to conduct, and are subjected to the specifications and variability of each printer. Here we develop a fast-throughput numerical approach that simulates the LPBF-AM process using a cellular automaton model of dynamic solidification and grain growth. This is accompanied by a polycrystal plasticity model that captures grain boundary strengthening due to complex grain geometry and furnishes the stress-strain curves of the resulting microstructures. Our approach connects the processing stage with the mechanical testing stage, thus capturing the effect of processing variables such as the laser power, laser spot size, scan speed, and hatch width on the yield strength and tangent moduli of the processed materials. When applied to pure Cu and stainless 316L steel, we find that laser power and scan speed have the strongest influence on grain size in each material, respectively.

Crack-free tungsten coating on ODS plate via a modified laser-based additive technique: Offset laser cladding

A modified laser-based additive manufacturing technique, offset laser cladding was introduced to achieve dense tungsten coating on an oxide dispersion-strengthened (ODS) substrate as a plasma facing material (PFM). Different from ordinary direct energy deposition (DED) which leads to incomplete melting of tungsten and excessive melting of ODS substrate, the offset laser cladding technique can achieve complete melting of tungsten while substrate melting is suppressed. Experimental conditions (i.e., laser power, scanning speed, powder size, offset distance and injection powder nozzle setting) were carefully calculated using two validated simulation models to minimize the consumption of valuable experimental resources. Tungsten coating using the offset laser cladding in an open chamber condition showed that dense coating was achieved with a pore size of 1–2 μm. The result is comparable to that of vacuum plasma spray (VPS) tungsten coating which requires a high-level vacuum chamber. A thin interface layer (2–5 μm) was formed between the tungsten coating and ODS substrate that can alleviate thermal damage due to a large thermal expansion coefficient difference. While a small amount of surface melting was involved, the microhardness test revealed that the ODS substrate was insignificantly affected by laser heating during the offset laser cladding.

Investigation on Optical Absorption and Reflection of Carbon Nanotubes Mixed Copper Composites for Laser Sintering Process Improvement

Selective laser sintering (SLS) of copper components manufactured via powder metallurgy is widely studied due to minimal material wastage. However, copper has poor optical absorption when exposed to infrared (IR) lasers, such as in laser-based additive manufacturing or laser surface processing. To address this issue, an innovative approach to enhance the optical absorption of copper powders during infrared laser sintering is presented in this study. Carbon nanotubes (CNTs) have several unique properties, including their high surface area, plasmonic response, excellent conductivity, and optical absorption properties. CNTs were mixed with copper powders at different weight percentages using an acoustic method. The resulting Cu-CNT compositions were fabricated into pellets. The Box-Behnken Design of Experiments methodology was used to optimize the IR laser processing conditions for sintering. Spectroscopic analysis was conducted to evaluate the reflection and thermal absorption of the IR wavelengths by the Cu-CNT composites. Density and hardness measurements were taken for the laser-sintered Cu-CNT pellets. The coating of copper powders with CNTs demonstrated enhanced optical absorption and correspondingly reduced reflection. Due to the enhanced optical absorption, increased control and sensitivity of the laser sintering process was achieved, which enabled improvement in the mechanical properties of strength, hardness, and density, while also enabling control over the composite thermal expansion coefficient. A maximum average hardness of 66.5 HV was observed. Indentation test results of the samples revealed maximum tangential and radial stresses of 0.148 MPa and 0.058 Mpa, respectively.