Analysis of printing time components and powder utilisation efficiency of metal selective laser melting process in case of 316L and Ti6Al4V materials

References

• O'Leary DE. Gartner's hype cycle and information system research issues. Int J Account Inf Syst. 2008;9(4):240–252. doi:10.1016/j.accinf.2008.09.001
   Google Scholar
• Afadar A, Guzzomi F, Rassau A, et al. Advances in metal additive manufacturing: a review of common processes, industrial applications, and current challenges. Appl Sci. 2021;11(3):1213. doi:10.3390/app11031213
   Google Scholar
• Ahn DG. Directed energy deposition (DED) process: state of the art. Int J Precis Eng Manuf-Green Tech. 2021;8:703–742. doi:10.1007/s40684-020-00302-7
   Web of Science ®Google Scholar
• Suwanpreecha C, Seensattayawong P, Vadhanakovint V, et al. Influence of specimen layout on 17-4PH (AISI 630) alloys fabricated by low-cost additive manufacturing. Metall Mater Trans A. 2021;52:1999–2009. doi:10.1007/s11661-021-06211-x
   Web of Science ®Google Scholar
• Lores A, Azurmendi N, Agote I, et al. A review on recent developments in binder jetting metal additive manufacturing: Materials and process characteristics. Powder Metall. 2019;62(5):267–296. doi:10.1080/00325899.2019.1669299
   Web of Science ®Google Scholar
• Herzog D, Seyda V, Wycisk E, et al. Additive manufacturing of metals. Acta Mater. 2016;117:371–392. doi:10.1016/j.actamat.2016.07.019
   Web of Science ®Google Scholar
• Wang L, Li Y, Zhou L, et al. Progress in additive manufacturing, additive repair and fatigue evaluation of aviation titanium alloy blades. Mater Res Lett. 2023;11(12):973–1012. doi:10.1080/21663831.2023.2275599
   Web of Science ®Google Scholar
• Tjandra J, Alabort E, Barba D, et al. Corrosion, fatigue and wear of additively manufactured Ti alloys for orthopaedic implants. Mater Sci Technol. 2023;39(18):2951–2965. doi:10.1080/02670836.2023.2230417
   Web of Science ®Google Scholar
• Wiese M, Leiden A, Rogall C, et al. Modeling energy and resource use in additive manufacturing of automotive series parts with multi-jet fusion and selective laser sintering. Procedia CIRP. 2021;98:358–363. doi:10.1016/j.procir.2021.01.117
   Google Scholar
• Zhou YH, Zhang ZH, Wang YP, et al. Selective laser melting of typical metallic materials: An effective process prediction model developed by energy absorption and consumption analysis. Addit Manuf. 2019;25:204–217. doi:10.1016/j.addma.2018.10.046
   Web of Science ®Google Scholar
• Pan X, Qiu C. Promoting columnar-to-equiaxed transition in AlCoCrFeNi high entropy alloy during selective laser melting by adding Cr3C2. Mater Res Lett. 2022;10(12):788–796. doi:10.1080/21663831.2022.2106798
   Web of Science ®Google Scholar
• Tan C, Zhou K, Ma W, et al. Selective laser melting of high-performance pure tungsten: parameter design, densification behavior and mechanical properties. Sci Technol Adv Mater. 2018;19(1):370–380. doi:10.1080/14686996.2018.1455154
   PubMed Web of Science ®Google Scholar
• Colopi M, Caprio L, Demir AG, et al. Selective laser melting of pure Cu with a 1 kW single mode fiber laser. Procedia CIRP. 2018;74:59–63. doi:10.1016/j.procir.2018.08.030
   Google Scholar
• Chen K, Wang C, Hong Q, et al. Selective laser melting 316L/CuSn10 multi-materials: Processing optimization, interfacial characterization and mechanical property. J Mater Process Technol. 2020;283:116701. doi:10.1016/j.jmatprotec.2020.116701
   Web of Science ®Google Scholar
• Kozak J, Zakrzewski T, Witt M, et al. Selected problems of additive manufacturing using SLS/SLM processes. Trans Aerospace Res. 2021;2021(1):24–44. doi:10.2478/tar-2021-0003
   Google Scholar
• Pimenov DY, Berti LF, Pintaude G, et al. Influence of selective laser melting process parameters on the surface integrity of difficult-to-cut alloys: comprehensive review and future prospects. Int J Adv Manuf Technol. 2023;127:1071–1102. doi:10.1007/s00170-023-11541-8
   Web of Science ®Google Scholar
• Philo A, Sutcliffe C, Sillars S, et al. A study into the effects of gas flow inlet design of the renishaw am250 laser powder bed fusion machine using computational modelling. Solid Freeform Fabrication 2017: Proceedings of the 28th Annual International; 2017. p. 1203–1219.
   Google Scholar
• Gunnerek R, Chen Z, Hryha E. Impact of high-productivity process parameters in powder bed fusion – laser beam on microstructure of stainless steel 316L. Eur J Mater. 2023;3:1. doi:10.1080/26889277.2023.2292987
   Google Scholar
• Dennis Edgard J, Kitashima T, Watanabe M. Effect of scan strategy on the formation of a pure nickel single-crystal structure using a flat-top laser beam via laser powder bed fusion. Sci Technol Adv Mater. 2023;24:1. doi:10.1080/14686996.2023.2201380
   Web of Science ®Google Scholar
• Yao L, Xiao Z, Hoo Z, et al. Mechanism analysis of grain growth dominated by alloy composition gradients during powder bed fusion. Mater Res Lett. 2023;11:(10):814–820. doi:10.1080/21663831.2023.2250826
   Web of Science ®Google Scholar
• An D, Xiao Y, Liu X, et al. Formation of two distinct cellular structures in 316L stainless steel fabricated by micro-laser beam powder-bed-fusion. Mater Res Lett. 2024;12(1):42–49. doi:10.1080/21663831.2023.2292076
   Web of Science ®Google Scholar
• Prashanth KG, Scudino S, Maity T, et al. Is the energy density a reliable parameter for materials synthesis by selective laser melting? Mater Res Lett. 2017;5(6):386–390. doi:10.1080/21663831.2017.1299808
   Web of Science ®Google Scholar
• Gusarov AV, Grigoriev SN, Volosova MA, et al. On productivity of laser additive manufacturing. J Mater Process Technol. 2018;261:213–232. doi:10.1016/j.jmatprotec.2018.05.033
   Web of Science ®Google Scholar
• Sefene EM. State-of-the-art of selective laser melting process: a comprehensive review. J Manuf Syst. 2022;63:250–274. doi:10.1016/j.jmsy.2022.04.002
   Web of Science ®Google Scholar
• Ali H, Ma L, Ghadbeigi H, et al. In-situ residual stress reduction, martensitic decomposition and mechanical properties enhancement through high temperature powder bed pre-heating of Selective Laser Melted Ti6Al4V. Mater Sci Eng A. 2017;695:211–220. doi:10.1016/j.msea.2017.04.033
   Web of Science ®Google Scholar
• Armstrong M, Mehrabi H, Naveed N. An overview of modern metal additive manufacturing technology. J Manuf Process. 2022;84:1001–1029. doi:10.1016/j.jmapro.2022.10.060
   Web of Science ®Google Scholar
• Hitzler L, Janousch C, Schanz J, et al. Direction and location dependency of selective laser melted AlSi10Mg specimens. J Mater Process Technol. 2017;243:48–61. doi:10.1016/j.jmatprotec.2016.11.029
   Web of Science ®Google Scholar
• Liu J, Dong S, Jin X, et al. Quality control of large-sized alloy steel parts fabricated by multi-laser selective laser melting (ML-SLM). Mater Des. 2022;223:111209. doi:10.1016/j.matdes.2022.111209
   Web of Science ®Google Scholar
• Schwerz C, Schulz F, Natesan E, et al. Increasing productivity of laser powder bed fusion manufactured Hastelloy X through modification of process parameters. J Manuf Process. 2022;78:231–241. doi:10.1016/j.jmapro.2022.04.013
   Web of Science ®Google Scholar
• Greco S, Gutzeit K, Hotz H, et al. Selective laser melting (SLM) of AISI 316L—impact of laser power, layer thickness, and hatch spacing on roughness, density, and microhardness at constant input energy density. Int J Adv Manuf Technol. 2020;108:1551–1562. doi:10.1007/s00170-020-05510-8
   Web of Science ®Google Scholar
• Yao D, An X, Fu H, et al. Dynamic investigation on the powder spreading during selective laser melting additive manufacturing. Addit Manuf. 2021;37:101707. doi:10.1016/j.addma.2020.101707
   Web of Science ®Google Scholar
• Drechsel K, Lubkowitz V, Albrecht L, et al. Development of an ultrasonically excited recoating process in laser powder bed fusion to process non-spreadable 316L powder. Powder Technol. 2024;432:119153. doi:10.1016/j.powtec.2023.119153
   Web of Science ®Google Scholar
• Wang L, Li EL, Shen H, et al. Adhesion effects on spreading of metal powders in selective laser melting. Powder Technol. 2020;363:602–610. doi:10.1016/j.powtec.2019.12.048
   Web of Science ®Google Scholar
• Gibbons DW, Govender P, van der Merwe AF. Metal powder feedstock evaluation and management for powder bed fusion: a review of literature, standards, and practical guidelines. Prog Addit Manuf. 2023. doi:10.1007/s40964-023-00484-x
   Google Scholar
• Lutter-Günther M, Gebbe C, Kamps T, et al. Powder recycling in laser beam melting: strategies, consumption modeling and influence on resource efficiency. Prod Eng Res Dev. 2018;12:377–389. doi:10.1007/s11740-018-0790-7
   Google Scholar
• Cordova L, Campos M, Tinga T. Revealing the effects of powder reuse for selective laser melting by powder characterization. JOM. 2019;71:1062–1072. doi:10.1007/s11837-018-3305-2
   Web of Science ®Google Scholar
• Yao D, Wang J, Li M, et al. Segregation of 316L stainless steel powder during spreading in selective laser melting based additive manufacturing. Powder Technol. 2022;397:117096. doi:10.1016/j.powtec.2021.117096
   Web of Science ®Google Scholar
• Alamos FJ, Schiltz J, Kozlovsky K, et al. Effect of powder reuse on mechanical properties of Ti-6Al-4 V produced through selective laser melting. Int J Refract Met Hard Mater. 2020;91:105273. doi:10.1016/j.ijrmhm.2020.105273
   Web of Science ®Google Scholar
• Barile C, Casavola C, Paramsamy Kannan V, et al. The influence of AlSi10Mg recycled powder on corrosion-resistance behaviour of additively manufactured components: mechanical aspects and acoustic emission investigation. Archiv Civ Mech Eng. 2022;22:52. doi:10.1007/s43452-022-00375-y
   Web of Science ®Google Scholar
• Chen Z, Xiang Y, Wei Z, et al. Thermal dynamic behavior during selective laser melting of K418 superalloy: numerical simulation and experimental verification. Appl Phys A. 2018;124:313. doi:10.1007/s00339-018-1737-8
   Web of Science ®Google Scholar
• Andani MT, Dehghani R, Karamooz-Ravari MR, et al. Spatter formation in selective laser melting process using multi-laser technology. Mater Des. 2017;131:460–469. doi:10.1016/j.matdes.2017.06.040
   Web of Science ®Google Scholar
• Bidare P, Bitharas I, Ward RM, et al. Fluid and particle dynamics in laser powder bed fusion. Acta Mater. 2018;142:107–120. doi:10.1016/j.actamat.2017.09.051
   Web of Science ®Google Scholar
• Keaveney S, Shmeliov A, Nicolosi V, et al. Investigation of process by-products during the Selective Laser Melting of Ti6AL4V powder. Addit Manuf. 2020;36:101514. doi:10.1016/j.addma.2020.101514
   Web of Science ®Google Scholar
• Guo Q, Zhao C, Escano LI, et al. Transient dynamics of powder spattering in laser powder bed fusion additive manufacturing process revealed by in-situ high-speed high-energy x-ray imaging. Acta Mater. 2018;151:169–180. doi:10.1016/j.actamat.2018.03.036
   Web of Science ®Google Scholar
• Kjer MB, Pan Z, Nadimpalli VK, et al. Experimental analysis and spatial component impact of the inert cross flow in open-architecture laser powder bed fusion. J Manuf Mater Process. 2023;7(4):143. doi:10.3390/jmmp7040143
   Google Scholar
• Young ZA, Guo Q, Parab ND, et al. Types of spatter and their features and formation mechanisms in laser powder bed fusion additive manufacturing process. Addit Manuf. 2020;36:101438. doi:10.1016/j.addma.2020.101438
   Web of Science ®Google Scholar
• Gunenthiram V, Peyre P, Schneider M, et al. Experimental analysis of spatter generation and melt-pool behavior during the powder bed laser beam melting process. J Mater Process Technol. 2018;251:376–386. doi:10.1016/j.jmatprotec.2017.08.012
   Web of Science ®Google Scholar
• Sutton AT, Kriewall CS, Leu MC, et al. Characterization of laser spatter and condensate generated during the selective laser melting of 304L stainless steel powder. Addit Manuf. 2020;31:100904. doi:10.1016/j.addma.2019.100904
   Web of Science ®Google Scholar
• Ladewig A, Schlick G, Fisser M, et al. Influence of the shielding gas flow on the removal of process by-products in the selective laser melting process. Addit Manuf. 2016;10:1–9. doi:10.1016/j.addma.2016.01.004
   Web of Science ®Google Scholar
• Anwar AB, Pham Q-C. Study of the spatter distribution on the powder bed during selective laser melting. Addit Manuf. 2018;22:86–97. doi:10.1016/j.addma.2018.04.036
   Web of Science ®Google Scholar
• Anwar AB, Pham Q-C. Selective laser melting of AlSi10Mg: effects of scan direction, part placement and inert gas flow velocity on tensile strength. J Mater Process Technol. 2017;240:388–396. doi:10.1016/j.jmatprotec.2016.10.015
   Web of Science ®Google Scholar
• Shen H, Rometsch P, Wu X, et al. Influence of gas flow speed on laser plume attenuation and powder bed particle pickup in laser powder bed fusion. JOM. 2020;72:1039–1051. doi:10.1007/s11837-020-04020-y
   Web of Science ®Google Scholar
• Ferrar B, Mullen L, Jones E, et al. Gas flow effects on selective laser melting (SLM) manufacturing performance. J Mater Process Technol. 2012;212(2):355–364. doi:10.1016/j.jmatprotec.2011.09.020
   Web of Science ®Google Scholar
• Guoqing Z, Junxin L, Xiaoyu Z, et al. Optimized design and key performance factors of a gas circulation filtration system in a metal 3D printer. Sci Rep. 2022;12:14267. doi:10.1038/s41598-022-18524-x
   Web of Science ®Google Scholar
• Pauzon C, Hoppe B, Pichler T, et al. Reduction of incandescent spatter with helium addition to the process gas during laser powder bed fusion of Ti-6Al-4 V. CIRP J Manuf Sci Technol. 2021;35:371–378. doi:10.1016/j.cirpj.2021.07.004
   Web of Science ®Google Scholar
• Anwar AB, Ibrahim IH, Pham Q-C. Spatter transport by inert gas flow in selective laser melting: A simulation study. Powder Technol. 2019;352:103–116. doi:10.1016/j.powtec.2019.04.044
   Web of Science ®Google Scholar
• Ficzere AHP. Finite element modeling of additive manufacturing in case of metal parts. Period Polytech Transp Eng. 2022;50(4):330–335. doi:10.3311/PPtr.19242
   Google Scholar
• Zhang X, Tuffile C, Cheng B. Computational modeling of the inert gas flow behavior on spatter distribution in selective laser melting. Solid Freeform Fabrication 2019: Proceedings of the 30th Annual International, 1362-1372, 2019, Austin, TX, USA; 2019.
   Google Scholar
• Lutter-Günther M, Hofmann A, Hauck C, et al. Quantifying powder losses and analyzing powder conditions in order to determine material efficiency in laser beam melting. Appl Mech Mater. 2017; 856:231–237. doi:10.4028/www.scientific.net/amm.856.231
   Google Scholar