Laser Powder Bed Fusion (LPBF) technologies are now being widely adopted across the global industrial landscape. New LPBF systems with multiple lasers and an expanded work area are entering the market, thereby enhancing both the production speed and the maximum size of 3D parts that can be produced. The aim was to investigate the aspects of upscaling LPBF processing parameters on the characteristic formation of stable single tracks, which are the primary building blocks for this technology. A number of LPBF systems were employed in this study, each operating independently and utilizing distinct parameter regimes, to produce the single tracks on a solid substrate deposited with a thin powder layer. The results demonstrated that the geometrical characteristics of single tracks are predominantly influenced by laser power and scanning speed when scanning a thin powder layer. The results also indicate that higher laser power and spot size can be used to produce stable tracks with increasing linear energy input. However, there are a number of nuances to be considered in increasing the performance.
Due to high functional properties such as resistance to mechanical, thermal and other physical and chemical impacts, metal matrix composites (MMCs) are widely used in high-tech industries for instance aerospace, automotive, medical, chemical, etc. Modern additive technologies that produce 3D products from metal powders using lasers are unique in terms of the possibility of obtaining new materials and complex parts with the required functional properties in one manufacturing cycle. Laser Powder Bed Fusion (L-PBF) technology makes it possible to greatly facilitate and accelerate the production of such products directly from their CAD (computer-aided design) models. The fundamentals of L-PBF technology provide a significant advantage both in the development of new materials and the manufacture of products from them. However, direct formation (in situ) and application of MMCs in the L-PBF process is constrained by insufficient elaboration of the fundamentals of the formation of these materials during laser processing and incomplete knowledge of the influence of the properties and nature of the initial materials and technological parameters of L-PBF on the final properties of MMCs. The investigation of the processes of forming metal matrix composites by laser-powder bed fusion is driven by the need to ensure stable and confident properties of L-PBF MMCs materials and parts regardless of the equipment used. In this research, the fundamentals of the L-PBF process during in-situ manufacturing of MMCs from dissimilar powders having different melting points and granulomorphometric properties are considered. Preliminary numerical simulations of thermal fields for different parameters of the L-PBF process on the powder mixture have been carried out.
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