Powder Bed Fusion Process Research Articles

Surface analysis in additive manufacturing: A systematic literature review regarding powder bed fusion processes

Abstract The analysis of surface effects in powder bed fusion additive manufacturing is the subject of intensive research activities. The aim of this paper is to provide an overview of the current state of knowledge and to gain a comprehensive understanding of this subject area. The paper is intended to enable researchers to select specific articles for their own further research context. In addition, a bibliometric analysis validates the data base. A discussion of the findings suggests that the criticality of the surface should be considered as a quality factor in the field of additive manufacturing by powder bed fusion processes. An accurate and reliable measurement is crucial for predicting component quality. There is a clear trend from two-dimensional measurements to three-dimensional measurements. Conducting comprehensive research is essential to improve the reliability and comparability of measurement results and to promote broad acceptance and application of this technology in the industry.

Optimized Build Orientation and Laser Scanning Strategies for Reducing Thermal Residual Stress in Topology-Optimized Automotive Components

This study investigates the reduction in thermal residual stress during the powder bed fusion (PBF) process in a non-standardized shape generated by topology optimization method in lightweight automotive part of brake caliper. While the caliper of the braking system for reducing the CO2 consumption in vehicle systems undergoes a redesign to increased strength and reduced weight, challenges arise due to biased melting area ratios in the topologically optimized design, causing the thermal deformation. To address this, our research proposes an efficient PBF scan strategy aimed at minimizing anisotropy and residual stress—a critical consideration for successful manufacturing. The effectiveness of the laser scan strategy is validated through testing on a brake dynamometer, following the JASO C406 test procedure, an authorized standard for commercial brake calipers. Furthermore, a comparative analysis between the conventional product and the proposed brake caliper highlights superior performance, particularly under lightweight conditions. This comprehensive approach contributes valuable insights to the field, offering a potential solution for overcoming manufacturing challenges associated with topologically optimized designs in automotive components.

Enhanced detection of surface deformations in LPBF using deep convolutional neural networks and transfer learning from a porosity model

Our previous research papers have shown the potential of deep-learning models for real-time detection and control of porosity defects in 3D printing, specifically in the laser powder bed fusion (LPBF) process. Extending these models to identify other defects like surface deformation poses a challenge due to the scarcity of available data. This study introduces the use of Transfer Learning (TL) to train models on limited data for high accuracy in detecting surface deformations, marking the first attempt to apply a model trained on one defect type to another. Our approach demonstrates the power of transfer learning in adapting a model known for porosity detection in LPBF to identify surface deformations with high accuracy (94%), matching the performance of the best existing models but with significantly less complexity. This results in faster training and evaluation, ideal for real-time systems with limited computing capabilities. We further employed Gradient-weighted Class Activation Mapping (Grad-CAM) to visualize the model’s decision-making, highlighting the areas influencing defect detection. This step is vital for developing a trustworthy model, showcasing the effectiveness of our approach in broadening the model’s applicability while ensuring reliability and efficiency.

Tribological effects of varying volumetric energy density in additive manufacturing of inconel 718

Abstract This study investigates the novel effects of varying volumetric energy density (VED) ratios on the tribological characteristics of Inconel 718 alloy fabricated using Laser Powder Bed Fusion (LPBF) process. Nine VED ratios were investigated, and samples underwent non-contact surface roughness tests, Vickers microhardness tests, and residual stress analysis. Notably, this study identified specific VED conditions where superior wear resistance was achieved, contributing new insights into optimizing LPBF parameters for tribological performance. Based on preliminary analysis, samples 1, 3, and 8 were selected for ball-on-disc wear testing. Sample 8, fabricated with 330 W laser power, 50 mm/s scan speed, 0.10 mm hatch spacing, and 0.05 mm layer thickness, demonstrated superior tribological behaviour with a 32.12% and 52.11% lower friction coefficient and 31% and 29.92% less mass loss compared to samples 1 and 3, respectively. The presence of γ-Ni, γ’-Ni3 (Al, Ti), γ-FCC, and γ’-L12 phases, along with microstructural features such as columnar and cellular dendritic structures, were confirmed via SEM and X-ray diffraction analyses. This study’s novel findings contribute valuable knowledge for optimizing Inconel 718 production via LPBF, particularly in enhancing wear resistance through tailored VED settings.

Advancing laser powder bed fusion with non-spherical powder: Powder-process-structure-property relationships through experimental and analytical studies of fatigue performance

This study investigates the multifaceted interdependencies among powder characteristics (i.e., non-spherical morphology and particle size ranging 50-120 or 75-175µm), laser powder bed fusion (L-PBF) process condition (i.e., contouring), post-process treatments (i.e., hot isostatic pressing (HIP) and mechanical grinding) on the pore, microstructure, surface finish, and fatigue behavior of additively manufactured Ti-6Al-4V samples. Microstructure analysis shows a phase transformation α′ → α+β microstructure after HIP treatment (at 899±14 °C for 2h under the applied pressure of 1034±34bar) of the as-built Ti-6Al-4V parts. The findings from pore analysis using micro-computed tomography (μ-CT) show an increase in sub-surface pores when relatively smaller powders are L-PBF processed including contouring. Surface optical profilometry reveals a decrease in surface roughness when fine powder is L-PBF including contouring. Pore analysis conducted through μ-CT reveals that the presence of lack-of-fusion pores within the L-PBF processed coarse powder is more pronounced when compared to the fine powder. Furthermore, HIP treatment does not eliminate these pores. The fracture failure in as-printed parts occurs at the surface, while the combination of HIP and mechanical grinding alters crack initiation to subsurface pore defects. Fractography reveals that HIP and as-built samples followed the facet formation and pseudo-brittle fracture mechanisms, respectively. Fatigue life assessments, supported by statistical analysis, indicate that mechanical grinding and HIP significantly enhanced fatigue resistance, approaching the benchmarks set by wrought Ti-6Al-4V alloy. A fatigue prediction model which considers the surface roughness as a micro-notch has been used.

Physical and chemical surface modification by laser polishing of CuZn42 parts produced by laser powder bed fusion

The widespread use of Cu-Zn alloys containing lead (Pb) in plumbing applications poses significant health risks due to potential Pb leaching into drinking water. In response to international legislation aimed at reducing or eliminating Pb in metal alloys, there is an increasing demand for environmentally friendly brass. In this experimental work, authors show that during the Laser Beam Powder Bed Fusion (PBF-LB) process of the CuZn42 (CW510L) alloy, small particles only a few microns large mixed with large particles that are hundreds of microns in size, are spattered from the material. Large particles show average Zn/Cu ratio around 0.22, while for small particles it increases up to 3, against a nominal value of 0.72 for the CW510L alloy. The fallout of such particles on the produced part enriches surface of Zn, thus altering the surface chemical composition with an increase in Zn concentration beyond the acceptance limit of 43 at.%. To restore the standard chemical composition of the surface, a treatment based on the ablation of the surface material by a laser beam was proposed. Results clearly show that, after the laser treatment, the chemical composition of the surface is completely restored, and the standard properties recovered.

S1aUnnotched fatigue behavior of the lased powder bed fused and hot isostatic pressed Inconel 718 at 600 °C

The microstructure and mechanical properties of hot isostatically pressed (HIP) Inconel 718 additively manufactured using the laser beam powder bed fusion (LPBF) process were investigated at 600 °C, with emphasis on the high cycle fatigue behavior evaluated using the rotating bend fatigue tests, and elucidation of the role of γ” precipitate size on the fatigue resistance. Experimental results show that the unnotched fatigue strength (σf) of the peak aged alloy improves only by 7% after HIP, as compared to that of the non-HIP peak aged alloy, despite a significant improvement in the ductility due to HIP. Over-aging the HIP alloy, however, led to a further enhancement (by ∼14%) in σf. Fractographic analyses suggest that the fatigue crack initiation occurs from the intrusions and extrusions on the fracture surface of both versions of the aged alloy. Microstructural investigations reveal the presence of persistent slip bands (PSBs) with different morphologies in peak- and over-aged microstructures. A change in the deformation mechanism due to the size of precipitates was identified to be the reason for the formation of nano-grains (through dynamic recrystallization) within the PSBs of the alloy with a coarse γ” microstructure. In several {110} grains, ∼5 μm thick nanocrystalline grain zones formed on the specimen surface; they completely suppressed the formation of PSBs and enhanced the fatigue resistance of the HIP LPBF IN718 alloy in the over-aged condition.

A layer-wise melting defects mitigation method in laser powder bed fusion process based on machine learning and fuzzy inference

A layer-wise melting defects mitigation method in laser powder bed fusion process based on machine learning and fuzzy inference

Comparative Analysis of Mechanical and Thermal Characteristics of 3D‐Printed Polyamide using Material Extrusion and Powder Bed Fusion Process with Industrial and Desktop Printers

AbstractPolyamide (PA) has excellent mechanical properties, making it versatile in various applications, including 3D printing. This paper comprehensively investigates and compares the mechanical, structural, thermal, and geometric properties of 3D‐printed PA12 samples produced with desktop and industrial printers using material extrusion (MEX) and powder bed fusion (PBF) processes. The mechanical tests included tensile, flexural, Charpy impact, Shore hardness, torsion, and water absorption tests. Additionally, scanning electron microscopy (SEM), differential scanning calorimetry (DSC), and melt volume rate (MVR) measurements are conducted. To verify printing accuracy from a biomedical perspective, 3D‐printed prosthetic fingers are subjected to geometric assessments. Industrial PBF samples show significantly higher values for most mechanical properties, including a tensile Young's modulus of 1776 ± 19.42 MPa, while the second highest value is 1419 ± 58.77 MPa (MEX desktop). Furthermore, the MVR of the PBF industrial samples is the highest (18.34 cm3/10 min ± 2.32 cm3/10 min) and this printer exhibits superior performance in printing accuracy than the other printers. The balanced print quality and mechanics make the PBF industrial printer the most recommended for medical device production, but lower‐priced desktop FFF printers can be a good alternative for simple, fast solutions that do not require high precision.

Integrating Metal–Organic Frameworks and Polyamide 12 for Advanced Hydrogen Storage Through Powder Bed Fusion

This paper introduces a pioneering approach that combines ex situ synthesis with advanced manufacturing to develop ZIF-67-PA12 Nylon composites with mixed-matrix membranes (MMMs), with the goal of enhancing hydrogen storage systems. One method involves producing MOF-PA12 composite powders through an in situ process, which is then commonly used as a base powder for powder bed fusion (PBF) to fabricate various structures. However, developing the in situ MOF-PA12 matrix presents challenges, including limited spreadability and processability at higher MOF contents, as well as reduced porosity due to pore blockage by polymers, ultimately diminishing hydrogen storage capacity. To overcome these issues, PBF is employed to form PA12 powder into films, followed by the ex situ direct synthesis of ZIF-67 onto these substrates at loadings exceeding those typically used in conventional MMM composites. In this study, ZIF-67 mass loadings ranging from 2 to 30 wt.% were synthesized on both PA12 powder and printed film substrates, with loadings on printed PA12 films extended up to 60 wt.%. ZIF-67-PA12-60(f) demonstrated a hydrogen capacity of 0.56 wt.% and achieved 1.53 wt.% for ZIF-67-PA12-30(p); in comparison, PA12 exhibited a capacity of 0.38 wt.%. This was undertaken to explore a range of ZIF-67 Metal–organic frameworks (MOFs) to assess their impact on the properties of the composite, particularly for hydrogen storage applications. Our results demonstrate that ex situ-synthesized ZIF-67-PA12 composite MMMs, which can be used as a final product for direct application and do not require the use of in situ pre-synthesized powder for the PBF process, not only retain significant hydrogen storage capacities, but also offer advantages in terms of repeatability, cost-efficiency, and ease of production. These findings highlight the potential of this innovative composite material as a practical and efficient solution for hydrogen storage, paving the way for advancements in energy storage technologies.

Modelling process monitoring data in laser powder bed fusion: A pragmatic route to additive manufacturing quality assurance

Quality assurance remains a significant challenge for laser powder bed fusion and metal additive manufacturing. Despite system manufacturers offering process monitoring as a possible solution, datasets are large and cumbersome with practical use limited without direct comparative data. Model datasets would enable individual build validation, highlight deviations, and facilitate intelligent build planning whereby challenging features or build strategies could be pre-emptively assessed.Herein a pragmatic approach has been developed to model process monitoring data from a commercial system using a relatively simple algorithm. Using a heuristic method, the algorithm response has been fitted to an experimental dataset to derive governing constants and their relationship to key process parameters. Predictability of constants and model fit has been shown to improve with increasing line energy up to a maximum R2=0.8. Algorithm variable trends, supported by corresponding sensitivity analysis, identified two different behavioural regimes. Under low linear energy density (<0.2J/mm) the cumulative spacetime proximity time-weight variable shows a low sensitivity index, characterised by a flat model response reflected in the experimental data. At higher energies (≥0.2J/mm) algorithm variables become more predictable, reflected in stabilising sensitivity indices, as measurements adopt a form characteristic of the cumulative spacetime proximity function.Effectiveness has been demonstrated through presentation of experimental and model data. Refining the methodology to accommodate noise, geometry, and systematic behaviours are identified as key steps to future development. This feasibility study has laid the groundwork for a generalised predictive tool, capable of realising the quality assurance ambitions promised by laser powder-bed fusion process monitoring.

Design and development of vacuum system for electron beam powder bed fusion process

A vacuum system is one of the crucial components of the Electron Beam-Powder Bed Fusion Process (EB-PBF). It ensures the generation of a high-intensity electron beam. This paper presents a vacuum system design for the EB-PBF process. The work chamber and EB gun chamber have been designed and verified using ANSYS workbench for stress, strain, and deformation limits and found satisfactory. The analytical calculations have been performed for all the pumps, considering the various gas loads during the process. After the design, the vacuum system has been fabricated and tested for its stability, ultimate vacuum, and leak rate. The helium leak test results show that all the joints have a leak rate better than 1 × 10−8 mbar l/s. Further, the analytical results of each pump have been compared with experimental results and found almost in line with the theoretical results. The results show that a pressure lower than 1 × 10−5 mbar and 5 × 10−6 mbar can be achieved in the work chamber and EB gun chamber in less than 23 min and 10 min respectively. The chamber was evacuated multiple times and found that the chamber could still hold pressure better than 1 × 10−2 mbar after 48 h.

A Study on the Compressive Behavior of Additively Manufactured AlSi10Mg Lattice Structures.

The mechanical behavior of the metallic components fabricated by additive manufacturing (AM) technologies can be influenced by adjustments in their microstructure or by using specially engineered geometries. Manipulating the topological features of the component, such as incorporating unit cells, enables the production of lighter metamaterials, such as lattice structures. This study investigates the mechanical behavior of lattice structures created from AlSi10Mg, which were produced using the laser beam powder bed fusion (LB-PBF) process. Specifically, their behavior under pure compressive loading has been numerically and experimentally investigated using ten different configurations. Experimental methods and finite element analysis (FEA) were used to investigate the behavior of body-centered cubic (BCC) lattice structures, specifically examining the effects of tapering the struts by varying their diameters at the endpoints (dend) and midpoints (dmid), as well as altering the height of the joint nodes (h). The unit cells were designed with varying parameters in such a way that dend is changed at three levels, while dmid and h are changed at two levels. Significant differences in Young's modulus, yield strength, and ultimate compressive strength between the various specimen configurations were observed both experimentally and numerically. The FEA underestimated the Young's modulus corresponding to the configurations with thinner struts in comparison to the higher values found experimentally. Conversely, the FEA overestimated the Young's modulus of those configurations with larger strut diameters with respect to the experimentally determined values. Additionally, the proposed FE method consistently underestimated the yield strength relative to the experimental values, with notable discrepancies in specific configurations.

Online Quality Control of Powder Bed Fusion with High-Resolution Eddy Current Testing Inductive Sensor Arrays.

This paper presents the development of a novel eddy current array (ECA) system for real-time, layer-by-layer quality control in powder bed fusion (PBF) additive manufacturing. The system is integrated into the recoater of a PBF machine to provide spatially resolved electrical conductivity imaging of the manufactured part. The system features an array of 40 inductive sensors spaced at 1 mm pitch and is capable of performing a full array readout every 0.192 mm at 100 mm/s recoater speed. Array scalability was achieved through the careful selection of the electromagnetic configuration, miniaturized and seamlessly integrated sensor elements, and the use of advanced mixed signal processing techniques. Experimental validation was performed on stainless steel 316L parts, successfully detecting metallic structures and confirming system performance in both laboratory and real-time PBF environments. The prototype achieved a signal-to-noise ratio (SNR) of 26.5 dB, discriminating metal from air and thus demonstrating its potential for improving PBF part design, process optimization, and defect detection.

A multiscale model for efficiently simulating laser powder bed fusion process with detailed microstructure and mechanical performance results

Numerical simulation is regarded as an important method for studying the mechanisms of additive manufacturing (AM), especially in building a multiscale simulation model. However, the conversion of physical phenomena and parameters across scales is complex, and the number of simulation elements often changes extremely, leading to an inherent conflict between simulation accuracy and efficiency. Therefore, this work introduces a model that balances the need for detailed grain morphology and overall simulation efficiency, to investigate the relationship between process parameters, microstructure, and mechanical performance during Inconel 718 laser powder bed fusion (L-PBF) process. The cellular automata - finite element method (CA-FEM) was used to simulate the melt pool forming and predict the microstructure evolution. Based on the CA result, the tensile process was simulated through crystal plasticity-finite element method (CP-FEM). Specially, the CA-FEM model was simplified and sliced layer-by-layer to reduce simulation time and data storage, supporting parallel computation. The prediction time for the microstructure growth of millions of elements was less than 1.5 h. The CP-FEM model was simplified by reasonably reducing elements in the representative volume element (RVE) model, improving the simulation efficiency by 73 %. The simulation results were validated through EBSD observation and tensile tests, showing good agreement with experimental results, with the final simulation error for mechanical performance not exceeding 10 %. The effects of process parameters on microstructure and mechanical performance were comprehensively discussed. This model supports the optimization of L-PBF process parameters for Ni-based alloys and provides a reference for improving the efficiency of multiscale simulations for other AM processes and materials.

Fabrication of high-performance Al-Cu-Mg matrix composites via laser powder bed fusion: Incorporating advanced materials and lattice structures

The Laser Powder Bed Fusion (LPBF) process for Al-Cu-Mg alloys, such as the 2024 alloy, is fraught with challenges, primarily due to thermal cracking and the complexity of fabricating lattice structures. This study presents a systematic exploration of the LPBF process capabilities for 2024 Al alloy, a representative Al-Cu-Mg alloy, by incorporating cost-effective micron-scale TiCN ceramic reinforcement particles. The introduction of TiCN significantly modifies the consolidation mechanisms of the 2024 Al alloy matrix during LPBF process, effectively eliminating thermal cracking, refining the matrix grain size, and therefore significantly enhancing the mechanical behavior of Al-Cu-Mg alloys. Nonetheless, this study incorporates advanced lattice structure design to the LPBF processing of 2024-5 vol% TiCN composite material. When compared to Cubic and Diamond structures, Schwarz one demonstrates superior compressive strength, which suggests that higher surface area design of the lattice structures may contribute to the improved mechanical properties. This research offers a novel and economical approach to the development of high-performance Al-Cu-Mg materials tailored for LPBF, laying a groundwork for applications in aerospace, automotive manufacturing, and other sectors.

Fatigue behavior of additively manufactured 316L stainless steel: Competition between the effects of defects and microstructure

Laser Powder Bed Fusion (LPBF) process, is becoming more and more widespread in industry. The possibilities of microstructural control offered by this process are an opportunity to study the contribution of the different length scales of microstructure to the fatigue behavior. This paper is devoted to the understanding of this fatigue behavior resulting from the interactions between the process induced defects and the different polycrystal length scales. Two distinct defect − microstructure competition regimes have been identified. The first concerns microstructures containing large Lack of Fusion (LoF) defects. These LoFs drastically reduce the fatigue life, while microstructure has no influence on the fatigue strength. The second regime concerns microstructures containing small defects. A limited effect of the polycrystalline microstructure was revealed. Furthermore, this paper demonstrates that the ratio between damage initiation defect size and grain size, used in literature to describe the defect and microstructure sensitivity of fatigue strength, is not applicable over a wide range of defects and microstructures, such as obtained by additive manufacturing processes. Finally, the comparison between the fatigue behavior of different microstructure and defect features shows that producing a finer microstructure improves fatigue strength despite the presence of a significant defect population.

Assessment of local mechanical properties of laser powder bed fused aluminium alloy by non-destructive testing based on FIMEC indentation

Laser powder bed fusion process is a versatile metal additive manufacturing process. Although significant progress has been made so far, there is still limited large-scale adoption of this technique by the industry. The main problems are repeatability and lack of proper knowledge. In this work, an innovative and non-destructive testing methodology, based on flat-top cylinder indentation, was used to define the mechanical properties of laser powder bed fused aluminium alloy to highlight any variations induced by the combination of process parameters, for global characterization, and by the building direction, for local characterization. Results show similar or improved global mechanical properties of the laser powder bed fused specimens when compared to traditional die-casted ones. Indentation tests highlight a local dependence of properties along the building direction in favor of the upper part of the samples.

Tribo-technological features of laser powder bed fusion process: scratch and wear resistance of AlSi10Mg aluminium alloy

Mechanical systems, regardless of their complexity, very often require that different parts must move relative to each other by sliding their surfaces, therefore appropriate tribological properties are needed. This request appears particularly evident for components fabricated through Metal Additive Manufacturing processes, due to their typical high surface roughness. In the current study, the Laser Powder Bed Fusion technique with optimized parameters is used to produce samples made of AlSi10Mg alloy. Their tribo-technological properties are investigated through progressive load scratch and dry ball-on-plate wear tests. Along with a global characterization, a local analysis has been performed to identify any variations induced by the building direction. The friction coefficient and the wear rate are generally higher than as-cast specimens. Finally, local trends suggest that the central parts of the samples average offer higher resistance to wear and scratch than the outer areas.

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.