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Additive Manufacturing: Innovations for Powderbed Fusion
1:30pm - 2:30pm
Session Chair: Dr. Dirk Herzog, Hamburg University of Technology, Germany
Location:Room 2 ICM
1:30pm - 2:00pm
Invited Talk: Advances on the Laser Powder Bed Fusion of Structural Materials: microstructure, processing and material strength
Institute of Materials Science, Joining and Forming, Graz University of Technology, Austria
2:00pm - 2:15pm
Laser-based powder bed fusion with 16 kW
Artur Leis1,2, Stefan Bechler1, Rudolf Weber1, Thomas Graf1
1Institut für Strahlwerkzeuge (IFSW), University of Stuttgart, Germany; 2Graduate School of Excellence advanced Manufacturing Engineering (GSaME), University of Stuttgart, Germany
Laser-based Powder Bed Fusion (LPBF) is typically performed at laser powers between 500-1000W, and laser beam diameters between 50-500µm. The generation of parts therefore requires a significant amount of time because the average power basically defines the productivity. To reduce the processing time, the laser power was set to 16kW and the laser beam diameter was adjusted to produce continuous melt beads. Additively manufactured samples of AlSi10Mg were used for the high-power experiments. The melting process was recorded with a high-speed camera. The generated beads were analysed metallographically to determine the extent and shape of the molten region, the crystallographic structure and the porosity. It was found that it was possible to generate continuous melt beads with laser beam diameters between 2.5-3.8mm at feed rates between 0.5-1.5m/s with a laser power of 16kW, at the expense of hydrogen-induced porosity. In the talk, the results will be presented and discussed.
2:15pm - 2:30pm
Manufacturing knowledge: model instead of experience, a big step towards reproducibility and first-time-right in the production of complex component geometries using PBF-LB/M
Hannes Korn1, Stefan Holtzhausen2, Claudia Ortmann3, Felix Gebhardt1, Ralph Stelzer2, Welf-Guntram Drossel1
1Fraunhofer Institute for Machine Tools and Forming Technology IWU, Germany; 2Technical University of Dresden, Institute of Machine Elements and Machine Design, Germany; 3Mathys Orthopädie GmbH, Germany
The cost structure and geometry freedom of laser powder bed fusion (PBF-LB/M) holds great potential for lightweight-capabilities, customization and on-demand manufacturing of metal parts. Obstacles currently exist in first-time-right manufacturing and reliable reproducibility under changing process conditions. Reasons are the many setting variables (laser-parameters, process-parameters, scan-strategy) and disturbance variables (powder-batch, operator, ambient conditions), which have a difficult to quantify influence on the quality characteristics of the component (warpage, surface-roughness, porosity).
Compared to the so far widespread experience-based parameterization of the process, statistical modeling has great potential for describing and understanding the effects of the setting- and disturbance variables on the quality characteristics quantitatively. The influence of scan-strategy and laser-parameters on the warpage and surfaces of PBF-LB/M-components is evaluated on cantilever-like bridge specimens according to an optimized experimental plan. The relation between setting variables and quality characteristics is quanified in a linear model approach afterwards and its predictive power is evaluated.