Analysis of Building Platform Inhomogeneities in PBF-LB/M Process on Alloy 718
Source abstract
Abstract
Additive Manufacturing (AM) processes, particularly PBF-LB/M, are considered advantageous due to their flexibility, which allows process engineers to design and fabricate intricate structures both in the prototyping and component manufacturing phases. It is well known that the behavior of the process directly impacts the quality of the materials and thereby induces inhomogeneities on the powder bed on the building platform. Several parameters can be tuned to keep the process under control, getting rid of process uncertainty and distinguishing aspects of a specific machine model. Such behavior requires an extended analysis of the powder bed inhomogeneities and the definition of limits in the printing process. In this work, carried out on Alloy 718 specimens printed using an EOS M290 machine, the inhomogeneities of the melt pool stability, density, and material properties were investigated based on three main factors: the amount of area melted or fused, the gas flow speed setpoint, and the location on the building platform. The test results for Track Stability, melt-pool shape, and porosity analysis show that criticality occurs when more than 50% of the building platform is exposed. This can be partly fixed by raising the differential pressure value.
Source: crossref · Quality: baseline
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Welding Techniques and Residual Stresses · Aluminum Alloy Microstructure Properties
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
Affiliations
Department of Engineering Science, Guglielmo Marconi University, 00193 Rome, Italy
Baker Hughes—Nuovo Pignone, Via Felice Matteucci 2, 50127 Florence, Italy
Department of Industrial, Electronic and Mechanical Engineering, Roma Tre University, 00146 Rome, Italy
References (52)
Show source-provided references
1. Metal Additive Manufacturing in Aerospace: A Review10.1016/j.matdes.2021.110008 ↗
2. Impact of Gas Flow Direction on the Crystallographic Texture Evolution in Laser Beam Powder Bed Fusion10.1080/17452759.2023.2169172 ↗
3. The Microstructure and Mechanical Properties of Deposited-IN718 by Selective Laser Melting10.1016/j.jallcom.2011.10.107 ↗
4. Flexible Manufacturing of Metallic Products by Selective Laser Melting of Powder10.1016/j.ijmachtools.2006.01.024 ↗
5. Binding Mechanisms in Selective Laser Sintering and Selective Laser Melting10.1108/13552540510573365 ↗
6. Single Track Formation in Selective Laser Melting of Metal Powders10.1016/j.jmatprotec.2010.05.010 ↗
7. Hagedorn, Y. (2016). Laser Additive Manufacturing of Ceramic Components, Elsevier.10.1016/B978-0-08-100433-3.00006-3 ↗
8. Linking Process, Structure, Property, and Performance for Metal-Based Additive Manufacturing: Computational Approaches with Experimental Support10.1007/s00466-015-1240-4 ↗
9. Optimal Process Conditions for Powder Bed Fusion and Analysis of Properties of Maraging Steel10.1007/s12540-023-01437-3 ↗
10. On the Influence of Laser Defocusing in Selective Laser Melting of 316L
11. Novel Single Crystalline-like Non-Equiatomic TiZrHfNbTaMo Bio-High Entropy Alloy (BioHEA) Developed by Laser Powder Bed Fusion10.1080/21663831.2022.2147406 ↗
12. The Effect of Energy Density on Texture and Mechanical Anisotropy in Selective Laser Melted Inconel 71810.1016/j.matdes.2020.108642 ↗
13. Excellent Strength–Ductility Balance of Sc-Zr-Modified Al–Mg Alloy by Tuning Bimodal Microstructure via Hatch Spacing in Laser Powder Bed Fusion10.1016/j.matdes.2022.110976 ↗
14. Crystallographic Texture Control of Beta-Type Ti–15Mo–5Zr–3Al Alloy by Selective Laser Melting for the Development of Novel Implants with a Biocompatible Low Young’s Modulus10.1016/j.scriptamat.2016.12.038 ↗
15. Effect of Volumetric Energy Density on Microstructure and Tribological Properties of FeCoNiCuAl High-Entropy Alloy Produced by Laser Powder Bed Fusion10.1080/17452759.2020.1848284 ↗
16. Crystallographic Orientation Control of Pure Chromium via Laser Powder Bed Fusion and Improved High Temperature Oxidation Resistance
17. Liu, X., Wang, K., Hu, P., He, X., Yan, B., and Zhao, X. (2021). Formability, Microstructure and Properties of Inconel 718 Superalloy Fabricated by Selective Laser Melting Additive Manufacture Technology. Materials, 14.10.3390/ma14040991 ↗
18. Mukherjee, T., Zuback, J.S., De, A., and DebRoy, T. (2016). Printability of Alloys for Additive Manufacturing. Sci. Rep., 6.10.1038/srep19717 ↗
19. Processing Parameters in Laser Powder Bed Fusion Metal Additive Manufacturing10.1016/j.matdes.2020.108762 ↗
20. Giorgetti, A., Baldi, N., Palladino, M., Ceccanti, F., Arcidiacono, G., and Citti, P. (2023). A Method to Optimize Parameters Development in L-PBF Based on Single and Multitracks Analysis: A Case Study on Inconel 718 Alloy. Metals, 13.10.3390/met13020306 ↗
21. Assessing Printability Maps in Additive Manufacturing of Metal Alloys10.1016/j.actamat.2019.07.005 ↗
22. Study of the Effects of Laser Power and Scanning Speed on the Microstructural Morphologies and Physical Properties of L-PBF Produced Ni52.39Ti47.6110.1016/j.jmrt.2023.11.146 ↗
23. Influence of Keyhole and Conduction Mode Melting for Top-Hat Shaped Beam Profiles in Laser Powder Bed Fusion10.1016/j.jmatprotec.2019.116514 ↗
24. Observation of Keyhole-Mode Laser Melting in Laser Powder-Bed Fusion Additive Manufacturing10.1016/j.jmatprotec.2014.06.005 ↗
25. Benchmark Models for Conduction and Keyhole Modes in Laser-Based Powder Bed Fusion of Inconel 71810.1016/j.optlastec.2023.109509 ↗
26. Influences of Processing Parameters on Surface Roughness of Hastelloy X Produced by Selective Laser Melting
27. Analytical Modeling of Lack-of-Fusion Porosity in Metal Additive Manufacturing10.1007/s00339-019-3092-9 ↗
28. Mitigation of Lack of Fusion Defects in Powder Bed Fusion Additive Manufacturing10.1016/j.jmapro.2018.10.028 ↗
29. Makoana, N.W., Yadroitsava, I., Möller, H., and Yadroitsev, I. (2018). Characterization of 17-4PH Single Tracks Produced at Different Parametric Conditions towards Increased Productivity of LPBF Systems—The Effect of Laser Power and Spot Size Upscaling. Metals, 8.10.3390/met8070475 ↗
30. Heat Transfer and Material Flow during Laser Assisted Multi-Layer Additive Manufacturing10.1063/1.4896751 ↗
31. Flow Field Analysis for Multilaser Powder Bed Fusion and the Influence of Gas Flow Distribution on Parts Quality10.1108/RPJ-12-2021-0351 ↗
32. Laser Additive Manufacturing of Zn Porous Scaffolds: Shielding Gas Flow, Surface Quality and Densification10.1016/j.jmst.2018.09.065 ↗
33. Densification Behavior of Pure Zn Metal Parts Produced by Selective Laser Melting for Manufacturing Biodegradable Implants10.1016/j.jmatprotec.2018.03.007 ↗
34. X-Ray Diffraction Measurements and Computational Prediction of Residual Stress Mitigation Scanning Strategies in Powder Bed Fusion Additive Manufacturing
35. Residual Stress Reduction in Ti-6Al-4V Parts Fabricated by Laser-Foil-Printing Process10.1016/j.optlastec.2024.111157 ↗
36. Effect of Scanning Strategy on Geometric Accuracy of the Circle Structure Fabricated by Selective Laser Melting10.1016/j.jmapro.2021.02.015 ↗
37. The Effect of Laser Scanning Strategies on Texture, Mechanical Properties, and Site-Specific Grain Orientation in Selective Laser Melted 316L SS10.1016/j.matdes.2020.108852 ↗
38. Effect of a Helium Gas Atmosphere on the Mechanical Properties of Ti-6Al-4V Alloy Built with Laser Powder Bed Fusion: A Comparative Study with Argon Gas
39. Laser Powder Bed Fusion in High-Pressure Atmospheres10.1007/s00170-018-2495-7 ↗
40. On the effect of shielding gas flow on porosity and melt pool geometry in laser powder bed fusion additive manufacturing
41. Argon-Helium Mixtures as Laser-Powder Bed Fusion Atmospheres: Towards Increased Build Rate of Ti-6Al-4V10.1016/j.jmatprotec.2019.116555 ↗
42. Mapping and Modelling Single Scan Track Formation in Direct Metal Selective Laser Melting10.1016/S0007-8506(07)60676-3 ↗
43. Single Track and Single Layer Formation in Selective Laser Melting of Niobium Solid Solution Alloy10.1016/j.cja.2017.08.019 ↗
44. Single Track Scanning Experiment in Laser Powder Bed Fusion Process10.1016/j.promfg.2018.07.110 ↗
45. On Selective Laser Melting of Inconel 718: Densification, Surface Roughness, and Residual Stresses10.1016/j.matdes.2020.108818 ↗
46. Peculiarities of single track formation from TI6AL4V alloy at different laser power densities by selective laser melting
47. Rapid L-PBF Printing of IN718 Coupled with HIP-Quench: A Novel Approach to Manufacture and Heat Treatment of a Nickel-Based Alloy10.1016/j.jmrt.2024.05.128 ↗
48. Mechanisms Driving High-Cycle Fatigue Life of as-Built Inconel 718 Processed by Laser Powder Bed Fusion10.1016/j.msea.2019.06.003 ↗
49. Thermal Design Considerations for a L-PBF Built Metal Component: Effects of Inter-Layer Cooling Time, Preheating Temperature and Gas Flow10.1088/1757-899X/1306/1/012020 ↗
50. Baldi, N., Giorgetti, A., Palladino, M., Giovannetti, I., Arcidiacono, G., and Citti, P. (2023). Study on the Effect of Preheating Temperatures on Melt Pool Stability in Inconel 718 Components Processed by Laser Powder Bed Fusion. Metals, 13.10.3390/met13101792 ↗
51. A critical review on the effects of process-induced porosity on the mechanical properties of alloys fabricated by laser powder bed fusion10.1007/s10853-022-06990-7 ↗
52. Spatter and Oxide Formation in Laser Powder Bed Fusion of Inconel 718