Laser Scanning Speed Research Articles

Laser Powder Bed Fusion Parameters Optimization for Enhanced Mechanical Properties of EOS Co-Cr Dental Alloy.

This research explores how variations in laser powder bed fusion (LPBF) parameters-laser power (P), scanning speed (v), and base plate preheating temperature (ϑp)-affect the mechanical properties of the EOS Co-Cr SP2 dental alloy. A central composite design (CCD) was used to optimize the process parameters. Mechanical testing focused on crucial properties for dental applications, including yield strength (Rp0.2), elongation (ε), toughness (KVa), and flexural strength (Rms). Microstructural analysis was conducted using light and electron microscopy, while XRD identified microstructural phases. Statistical analysis (ANOVA, Scheffé post hoc test, α = 0.05) revealed significant effects of P, v, and ϑp on the mechanical properties. Response surface models (RSMs) were developed, and optimal parameters were determined to achieve maximum toughness and flexural strength. Maximum values were obtained with laser power above 205 W and base plate preheating at 310 °C. The mathematical model predicted toughness values with less than 5% deviation from experimental results, indicating high accuracy.

Characterizing the as-built surface topography of Inconel 718 specimens as a function of laser powder bed fusion process parameters

Purpose The ability to use laser powder bed fusion (LPBF) to print parts with tailored surface topography could reduce the need for costly post-processing. However, characterizing the as-built surface topography as a function of process parameters is crucial to establishing linkages between process parameters and surface topography and is currently not well understood. The purpose of this study is to measure the effect of different LPBF process parameters on the as-built surface topography of Inconel 718 parts. Design/methodology/approach Inconel 718 truncheon specimens with different process parameters, including single- and double contour laser pass, laser power, laser scan speed, build orientation and characterize their as-built surface topography using deterministic and areal surface topography parameters are printed. The effect of both individual process parameters, as well as their interactions, on the as-built surface topography are evaluated and linked to the underlying physics, informed by surface topography data. Findings Deterministic surface topography parameters are more suitable than areal surface topography parameters to characterize the distinct features of the as-built surfaces that result from LPBF. The as-built surface topography is strongly dependent on the built orientation and is dominated by the staircase effect for shallow orientations and partially fused metal powder particles for steep orientations. Laser power and laser scan speed have a combined effect on the as-built surface topography, even when maintaining constant laser energy density. Originality/value This work addresses two knowledge gaps. (i) It introduces deterministic instead of areal surface topography parameters to unambiguously characterize the as-built LPBF surfaces. (ii) It provides a methodical study of the as-built surface topography as a function of individual LPBF process parameters and their interaction effects.

Laser-induced the enhancement of Raman scattering performance in WO3-x/Ag composite films

Non-stoichiometric tungsten oxide (WO3-x) has controllable defects, high charge density, and good synergy with other materials to exhibit good surface-enhanced Raman scattering (SERS) properties. Its heterojunction structure provides an opportunity to develop high-quality and low-cost SERS substrates. This study obtained WO3-x/Ag composite thin films were obtained by Nd: YAG fiber pulsed laser modification at ambient conditions. The effects of interactions between heterojunctions and laser modification on the samples’ morphology, composition, and optical properties were investigated. The absorption peaks exhibited a red shift by varying the laser scan speeds, and the SERS properties of the sample were evaluated by methylene blue (MB) dye. The results show that the laser-modified WO3-x/Ag films have good stability as SERS substrates. The characteristic peaks of MB can still be detected after 90 days in the air. The WO3-x/Ag films also have good homogeneity and a low detection limit, with a limit of detection (LOD) as low as 10−7 M, and an enhancement factor as high as 1.34 × 104. The simulated results by the finite difference in time domain (FDTD) showed substantial agreement with those of the experimental ones.

Experimental Study and Random Forest Machine Learning of Surface Roughness for a Typical Laser Powder Bed Fusion Al Alloy

Surface quality represents a critical challenge in additive manufacturing (AM), with surface roughness serving as a key parameter that influences this aspect. In the aerospace industry, the surface roughness of the aviation components is a very important parameter. In this study, a typical Al alloy, AlSi10Mg, was selected to study its surface roughness when using Laser Powder Bed Fusion (LPBF). Two Random Forest (RF) models were established to predict the upper surface roughness of printed samples based on laser power, laser scanning speed, and hatch distance. Through the study, it is found that a two-dimensional (2D) RF model is successful in predicting surface roughness values based on experimental data. The best and minimum surface roughness is 2.98 μm, which is the minimum known without remelting. More than two-thirds of the samples had a surface roughness of less than 7.7 μm. The maximum surface roughness is 11.28 μm. And the coefficient of determination (R2) of the model was 0.9, also suggesting that the surface roughness of 3D-printed Al alloys can be predicted using ML approaches such as the RF model. This study helps to understand the relationship between printing parameters and surface roughness and helps print components with better surface quality.

Molecular dynamics research on the effect of selective laser melting parameters on porosity and properties of parts

Selective laser melting (SLM) is considered as a new production technology which has the potential to produce amorphous alloy parts. However, pores are often observed in parts prepared by SLM, which seriously affect the properties and life of the parts. In this work, an atomic model for SLM forming of Cu50Zr50 amorphous alloy is established. The effects of laser power and scanning speed on the porosity and mechanical properties of parts fabricate by SLM are researched using molecular dynamics methods. The results indicate that increasing laser power or reducing laser scanning speed could enhance the laser energy input of the molten pool and increase the molten pool temperature, which could improve the fluidity of the metal melt and prolong the existence time of the molten pool. The molten metal could fully fill the gaps between powders, which reduces the porosity and is beneficial to obtain dense parts. The tensile strength of samples formed by SLM is positively correlated with their porosity. Stress concentration occurs in the system with through holes and internal pores. Defects expand and interconnect rapidly under stress concentration, which leads to a decrease in strength and plasticity. The porosity could be reduced by adjusting the process parameters, thus improving the mechanical properties of the parts. This study provides a theoretical reference for a deeper understanding of the formation mechanism of SLM pores and the development of advanced alloys with high density.

A Study on the Green Laser Weldability of Copper-aluminum Battery Materials

Copper is widely utilized in electric vehicle batteries due to its excellent electrical conductivity, lightweight, and excellent corrosion resistance. However, copper has a high reflectivity of about 97% for infrared lasers, which makes it difficult to achieve stable welding quality. This study investigated using a green laser to weld nickel-coated copper and aluminum materials. After performing welding by changing the laser power and scan speed, the weld cross-section was observed with an optical microscope, and it was confirmed that the welding penetration depth and bead width increased as the heat input increased. The spatter on the bead surface and defects such as pores and cracks in the weld were caused by excessive heat input. Analysis of the weld cross-section using SEM-EDS showed that high heat input increased the formation of intermetallic compounds including CuAl2 and Cu9Al4. The mechanical properties of the weld were examined using a shear tensile test. The analysis results showed that intermetallic compounds caused brittleness in the weld joint, which lowered mechanical properties and caused defects such as pores and cracks. P60 (1.2 kW, scan speed: 250 mm/s), P80 (1.6 kW, scan speed: 375 mm/s), and P100 (1.2 kW, scan speed: 375 mm/s) were examples of excellent mechanical quality. The fastest welding condition, P100 (power: 2 kW, scan speed: 450 mm/s), was suggested as the most efficient welding condition.

Effect of Laser Powder Bed Fusion Parameters on the Evolution of Melt Pool, Densification, Microstructure, and Hardness in 420 Stainless Steel Parts

Laser powder bed fusion (LPBF) involves depositing, melting, and solidifying metal powder particles layer by layer to create 3D components. In this study, a deep fundamental understanding on how process parameters—laser power, scan speed, and hatch spacing—affect the melt pool, densification, microstructure, hardness, and thermal behavior of 420 stainless steel (420SS) parts produced by such technology is provided. The conducted investigation considers five levels of laser power and hatch spacing, and four scan speeds. Optimal single tracks, based on geometry and profile, are achieved with laser powers between 40 and 80 W and a scan speed of 10 mm s−1. In the multitrack analysis, it is indicated that a dense, smooth surface is obtained with a hatch spacing of 250 μm, corresponding to an overlapping rate of ≈30%. The 420SS samples show high densification (≈99%) and low surface roughness (≈3.62 μm). The microstructure consisted of martensite laths and retained austenite. The hardness and thermal conductivity of the samples are measured at 540 HV and 15.3 W m−1 K−1, respectively. In this study, the understanding of the process–structure–property relationships in LPBF of 420SS is expanded.

Optimization of laser cladding powder ratio and process parameters based on MOGWO algorithm

Optimizing the process parameters is crucial to obtaining a high-quality fusion coating. The fitted regression model for each response was then analyzed by creating a central composite test with process parameters and power ratios (laser power, scanning speed, and Ni-clad graphite content) as inputs and the quality of the fused coating (dilution rate, microhardness, and width of the fused coating) as responses. The laser cladding process parameters and power ratios were optimized using the multi-objective Gray Wolf Optimization (MOGWO) algorithm. The best combinations of process parameters and power ratios were laser power of 1596 W, scanning speed of 21.7 mm/s, and Ni-clad graphite percentage of 18.4 %. Experimental validation demonstrates the superiority and accuracy of the MOGWO algorithm. The dilution rate of the optimized fusion-clad coating is increased by 47.4 % and the microhardness is increased by 17.8 %.

Laser powder bed fusion of a nanocrystalline Finemet Fe-based alloy for soft magnetic applications

The aim of this work is to explore the laser powder bed fusion (LPBF) processability window of the nanocrystalline soft magnetic Finemet alloy. With that purpose, several laser power and scan speed values and a meander scanning strategy were probed to process simple geometry specimens. Good dimensional accuracy was obtained within the entire processing window investigated. Relative densities as high as 89% were achieved for processing conditions including high laser power and low scan speeds. The fraction of amorphous phase, which peaked at 49%, was found to be mostly dependent on the scan speed and only slightly influenced by the laser power. The microstructure of the crystalline domains is formed by ultrafine, equiaxed grains with random orientations. Irrespective of the processing conditions, the LPBF-processed samples exhibit a similar saturation magnetization, lower permeability, and higher coercivity than fully amorphous melt-spun ribbons of the same composition. The coercive field of the additively manufactured specimens is fairly independent of the relative density and exhibits a moderate inverse variation with the amorphous fraction. Consistent with earlier works, this study suggests that the average grain size is an important contributor to coercivity.

Simulation and experimental study of femtosecond laser ablation mechanisms of NiCoCrAlY coatings

To enhance the adhesion of turbine blade thermal barrier coating systems using the LST method, a thorough understanding of the ablation mechanism of NiCoCrAlY bond coat material by femtosecond laser systems is essential for producing high-quality textured grooves. This study systematically investigates the ablation mechanisms of NiCoCrAlY material, exploring the effects of laser energy density, laser scanning speed, and the number of laser scans on the ablation of NiCoCrAlY. Numerical simulations based on the two-temperature model were conducted, providing a comprehensive analysis of thermal effects, heat accumulation, and material response during the laser ablation process. The experimental results indicate that 1) the ablation phenomenon caused by heat accumulation becomes evident as the laser energy density increases from 1.948 J/cm2 to 4.521 J/cm2, with the accumulated heat reaching 1525.2 K, leading to distinct melting residues and heat-affected zones on the groove walls. 2) The change in laser scanning speed also affects heat accumulation. Using a laser scanning speed of 800 mm/s results in a high material removal rate, smooth machined walls, and a uniform surface with no significant heat-affected zones. 3) Excessively high numbers of laser scans shift the laser focus to the bottom of the groove. The high concentration of laser energy causes intense localized ablation, forming sharp bases with numerous cracks and melting residues. To achieve efficient and high-quality laser ablation, it is necessary to ensure that the number of scans remains below 40.

Determination of process parameters for additive manufacturing with Inconel 718 powder

Abstract In this study, the additive manufacturing (AM) of Inconel 718 was investigated, and the processing parameters can affect the mechanical properties of the product. The five-axis laser cladding composite processing machine Tongtai AMH-630 is used, and the laser power is set to 800W based on the thermal impact of the laser on the base plate. However, the laser scanning speed (600-1200mm/min) and powder feed rate (3~15g/min) are not arbitrary combinations. It is recommended to present the feed per unit length in g/mm, which seems to be more clearly expressed. Regardless of changes in laser scanning speed and wheel speed, it is a reasonable decision to control the combination of the two at about 0.01-0.013g/mm. Through single-pass cladding experiments, we select different combinations of laser scanning speed and powder feed rate with a cladding aspect ratio in the range of 3:1 to 4:1. In the multi-pass cladding experiment, an overlap rate of 30% was used as the plane cladding spacing; a spacing of 80% of the cladding height was used as the stacking height. This study uses scanning speeds of 600, 700, 800, 1000 and 1200mm/min to clad a rectangular body. Tensile test specimens were processed using a CNC lathe, and tensile tests were conducted to obtain variations in tensile strength and elongation at different scanning speeds. The mechanical properties of both will decrease as the scanning speed increases. At a scanning speed of 600mm/min, its tensile strength is comparable to that of Inconel 718 standard materials; but its elongation is 61% of that of standard materials. If Hot Isostatic Pressing (HIP) is applied after cladding, it seems that a higher scanning speed can achieve a performance closer to that of standard materials.

Influence of laser power and scanning speed on microstructure evolutions and mechanical properties of the SLM fabricated Al-Mg-Mn-Sc-Zr alloy

The Al-Mg-Mn-Sc-Zr alloy is fabricated by selective laser melting (SLM). The influence of laser power and scanning speed on microstructure evolutions and mechanical properties is studied in this research. Results indicate that increasing laser power can refine grain structures and reduce anisotropy on the printing surface. However, the increase in laser power will enhance the residual stress inside the alloy, leading to a decrease in elongation. The scanning speed affects the molten pool energy input and cooling rate. When the scanning speed is between 750mm/s-1250mm/s, the alloy achieves a good grain refinement effect and weak texture strength. In addition, there exists a large number of nano-scaled Al3(Sc,Zr) particles precipitated during solidification and the subsequent annealing process, which can significantly enhance yield strength of the alloy. Overall, the Al-Mg-Mn-Sc-Zr alloy has a wide SLM forming window. When the laser power ranges from 200W to 250W, the scanning speed ranges from 750mm/s to 1250mm/s, and the volume energy density ranges from 80J/mm3 to 130J/mm3, the Al-Mg-Mn-Sc-Zr alloy can obtain good formability and mechanical property.

An analytical model for estimating process parameters input in L-DED based on bead geometry

Additive manufacturing of metal alloys via laser Directed Energy Deposition (L-DED) has been gaining popularity due to its potential to repair and create new features/components, enabling new applications for built parts. The success of L-DED operations hinges on the precise control of printing parameters, including laser power, scanning speed, and powder feed rate. These parameters significantly influence heat distribution during printing, directly impacting the quality of the resulting parts. Thus, defining an efficient methodology to find a good correlation between these parameters for the printing process is crucial to boost part production, as it reduces the time-consuming trial-and-error parameter tuning process. In this context, our study introduces an analytical model that predicts printing parameters based on the deposited material volume along track lines. Deposition was carried in stainless steel 316L with different values for laser power (ranging from 500 to 750W with 50W increments), scanning speed (from 400 to 700mm/min with 100mm/min increments), and powder feed rate (6.4,8.0 and 10.0g/min). The experimental data verified the effectiveness of the proposed model, demonstrating its potential to standardize the first step of printing process and expedite the initial search for optimal printing parameters in L-DED. The model provided accurate initial estimates of laser power, with a maximum relative error of 12%, particularly for the optimum mass flow rate (ṁ) of 8.0g/min. Beyond its benefits to the L-DED process, this analytical solution contributes to experimental practices by offering an efficient method for predicting material deposition volume during printing. Thus, our work underscores the significance of optimizing printing parameters to achieve high-quality parts and provides a valuable reference for future research and studies in the field of L-DED.

Operando visualization of porous metal additive manufacturing with foaming agents through high-speed x-ray imaging

Porous metals find extensive applications in soundproofing, filtration, catalysis, and energy-absorbing structures, thanks to their unique internal pore structure and high specific strength. In recent years, there has been an increasing interest in fabricating porous metals using additive manufacturing (AM), leveraging its unique advantages, including improved design freedom, spatial material control, and cost-effective small-batch production. In this study, we conducted pioneering operando visualization of AM porous metal using a laser powder bed fusion (L-PBF) setup combined with a high-speed synchrotron x-ray imaging system. Single track printing experiments using Ti6Al4V (Ti64) combined with titanium hydride (TiH2) and sodium carbonate (Na2CO3) as foaming agents, with varying mixing ratios were performed under different processing conditions. The results elucidate the dynamic development of porosity formation. The average pore size is significantly influenced by the particle size of foaming agents when pore coalescence is absent. For all foaming agent content tested in the current study, the number of pores is found to be more sensitive to changes in laser power than in laser scanning speed. Increasing linear energy density (increasing laser power or reducing laser scanning speed) promotes the foaming agent activation thereby porosity formation. However, high linear energy density skews pore distribution towards the surface despite forming deeper melt pools. In addition, the impact of additional factors including foaming agent’s laser absorptivity and decomposition kinetics with respect to AM time scales should be carefully considered to avoid ineffective activation of foaming agents during the AM of porous metals.

Systematic Investigation into Laser Powder Bed Fusion of Ti-5553 through Single-track and Multi-layer Studies for Tailored Manufacturing Solutions

Laser Powder Bed Fusion (LPBF) is recognized as an appealing fabrication process for producing metallic parts with customized properties. In the current research, a comprehensive approach is employed to systematically correlate single-track and multi-layer fabrication, aiming to generate a reliable process map, assess the effect of process parameters on the properties of LPBF-made Ti-5553, and guide the manufacturing of tailored structures. Based on single-track morphology, melt pool geometry, and multi-layer density, 30 combinations of laser power and scanning speed were categorized into three groups to identify the desirable process parameters. The investigation of single-tracks and multi-layers reveals that deeper melt pools, created with higher energy input, result in a more elongated grain structure, higher α phase content, increased strength and hardness, and reduced ductility. It is observed that achieving higher ductility involves a slight decrease in strength. Specifically, a substantial increase of ∼65% in ductility occurs with only a ∼3.5% reduction in strength. Also, it is found that the volumetric energy density (VED) alone is not sufficient as a design parameter, and the significant process parameters (e.g., laser power and scanning speed) should be considered, as two samples with the same VED yield different properties.

On microstructure development during laser melting and resolidification: An experimentally validated simulation study

Integrating experiment and simulation provides invaluable insights into the critical parameters that determine the microstructure of alloys produced by additive manufacturing. Here, the grain structure formation due to solidification during single pass laser scans (mimicking bead-on-plate single tracks) on a 316L stainless steel is studied in situ inside a scanning electron microscope that is directly integrated with a continuous-wave laser. The grain size distribution before melting is used as an initial condition in a coupled phase-field/thermal multiphysics modeling framework. The predicted resolidified microstructures are found to agree favorably with those observed experimentally for multiple laser powers and scan velocities, indicating the validity of the overall model. Grain morphology is analyzed quantitatively, and the top surfaces are compared between the experiments and simulations. Analysis of the three-dimensional grain shapes predicted by the simulations shows that the length of the major axis of the resolidified grains is sensitive to laser power and scan speeds, while the length of the minor axis is not. Furthermore, the preferential alignment of the major axes of the grains depends on the melt pool geometry.

Optimizing Lasing Parameters for Fabricating an Efficient Flexible Electrothermal Heater Based on Laser-Induced Graphene

This work involved fabrication of an efficient thin film heater from 100 μm thick polyimide (PI) sheet by scribing it using a carbon dioxide lasing machine through optimizing laser power (P), scanning speed (SS), and pulses per inch (PPI). A 15 mm × 15 mm square pattern was designed using CorelDRAW software and scribed in a rastering mode on top of PI with the help of Universal Control Panel (UCP) software of the laser machine. Laser power of 8 %, SS of 4 % and PPI of 1000 were obtained as optimal parameters for producing laser induced graphene (LIG). This LIG exhibited a low sheet resistance of approximately 16.64 Ω/sq and was thermally stable on the PI substrate even after 30 cycles of repeated heating and cooling. The LIG was found to be highly porous with the aid of scanning electron microscope (SEM) and its structure was crystalline from XRD patterns. FTIR was conducted and showed disappearance of functional groups in PI after treatment with the laser beam. Our developed LIG heater showed great electrothermal performance with maximum temperature of approximately 288.7 °C, rate of temperature rise of 107.06 °Cs-1, and time of 1.85 s to reach 63 % of temperature difference at a low input voltage of 6 V with homogeneous temperature distribution seen in the thermal images taken using FLIR camera. This LIG heating element can be placed in confined spaces because of its flexibility, thinness, and lightness. Additionally, its efficient joule heating effect attracts many applications such as seat warmers, anti-fogging equipment, food shelf displays, etc.

Integrated modeling to control vaporization-induced composition change during additive manufacturing of nickel-based superalloys

A critical issue in laser powder bed fusion (LPBF) additive manufacturing is the selective vaporization of alloying elements resulting in poor mechanical properties and corrosion resistance of parts. The process also alters the part’s chemical composition compared to the feedstock. Here we present a novel multi-physics modeling framework, integrating heat and fluid flow simulations, thermodynamic calculations, and evaporation modeling to estimate and control the composition change during LPBF of nickel-based superalloys. Experimental validation confirms the accuracy of our model. Moreover, we quantify the relative vulnerabilities of different nickel-based superalloys to composition change quantitatively and we examine the effect of remelting due to the layer-by-layer deposition during the LPBF process. Spatial variations in evaporative flux and compositions for each element were determined, providing valuable insights into the LPBF process and product attributes. The results of this study can be used to optimize the LPBF process parameters such as laser power, scanning speed, and powder layer thickness to ensure the production of high-quality components with desired chemical compositions.

Elastocaloric effect of NiTi shape memory alloys manufactured by laser powder bed fusion

To address the challenges posed by the complex processing of NiTi alloys, the additive manufacturing technology has been employed for the preparation of NiTi alloys samples. Up to now, there is limited research on the elastocaloric effects of NiTi alloys manufactured by LPBF. This study focused on the utilization of laser powder bed fusion (LPBF) to fabricate NiTi samples, with a particular emphasis on the influence of laser power, scanning speed and hatch spacing on the microstructure and properties of NiTi alloys. The results indicated that the process parameters affect the stress hysteresis of superelasticity by influencing the Ni content in the NiTi alloys. The higher Ni content, the lower the stress hysteresis. In addition, the critical stress for plastic deformation of the texture in the <001> direction in NiTi alloys is the smallest. When only the P was changed, the proportion of the texture in the <001> direction in the sample increased with the increase of P, the proportion of plastic deformation increased, and the degree of recovery also gradually decreased. Furthermore, at a specific temperature, 10 K higher than the end temperature of austenite transformation, each sample exhibited good superelasticity. In particular, the 1st cooling capacity of the sample with the best elastocaloric effect reached 11.0 K, which was superior to other results obtained by LPBF under similar compressive strain levels.

Molten pool macroscopic thermodynamic analysis during selective laser melting of AlSi10Mg: Simulations and experiments

In this study, the three-dimensional (3D) finite element model of COMSOL Multiphysics was used to simulate the thermodynamic behavior of the AlSi10Mg molten pool (MP) during selective laser melting (SLM), and the results were verified by multiple groups of single-track SLM experiments. The simulations take into account numerous thermophysical phenomena such as fluid flow, heat conduction, heat radiation, and fluid mass transfer. The influence of laser power, scanning speed, and other process parameters on temperature, shape, and size of MP was investigated. The simulated results and the experimental validation show that the model predictions are highly consistent with the measured data for most sets laser parameters, especially the MP width of 142 μm vs. 145 μm, depth of 53 μm vs. 56 μm at a laser power of 250 W and a scanning speed of 1000 mm/s, which confirms the reliability and accuracy of the model. Furthermore, the model innovatively forecasts the critical parameters for solidification in MP and delves into the intricate relationship between the position in MP and key parameters such as temperature gradient, cooling rate, and solidification rate. The model's versatility ensures its applicability to SLM simulation processes across diverse alloys and varying parameters. This research not only enhances our comprehension of SLM but also establishes a scientific foundation for optimizing processes, controlling microstructures, and enhancing material performance.