Relevant bibliographies by topics / PBF-LB/M

Academic literature on the topic 'PBF-LB/M'

Author: Grafiati
Published: 14 March 2023

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Journal articles on the topic "PBF-LB/M"

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Schneck, Matthias, Max Horn, Maik Schindler, and Christian Seidel. "Capability of Multi-Material Laser-Based Powder Bed Fusion—Development and Analysis of a Prototype Large Bore Engine Component." Metals 12, no. 1 (December 25, 2021): 44. http://dx.doi.org/10.3390/met12010044.

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Additive Manufacturing (AM) allows the manufacturing of functionally graded materials (FGM). This includes compositional grading, which enables the allocation of desired materials corresponding to local product requirements. An upcoming AM process for the creation of metal-based FGMs is laser-based powder bed fusion (PBF-LB/M) utilized for multi-material manufacturing (MM). Three-dimensional multi-material approaches for PBF-LB/M are stated to have a manufacturing readiness level (MRL) of 4 to 5. In this paper, an advancement of multi-material technology is presented by realizing an industry-relevant complex part as a prototype made by PBF-LB/M. Hence, a multi-material injection nozzle consisting of tool steel and a copper alloy was manufactured in a continuous PBF-LB/M process. Single material regions showed qualities similar to the ones resulting from mono-material processes. A geometrically defined transition zone between the two materials was achieved that showed slightly higher porosity than mono-material regions. Nevertheless, defects such as porosity, cracks, and material cross-contamination were detected and must be overcome in further MM technology development.
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Heiland, Steffen, Benjamin Milkereit, Kay-Peter Hoyer, Evgeny Zhuravlev, Olaf Kessler, and Mirko Schaper. "Requirements for Processing High-Strength AlZnMgCu Alloys with PBF-LB/M to Achieve Crack-Free and Dense Parts." Materials 14, no. 23 (November 25, 2021): 7190. http://dx.doi.org/10.3390/ma14237190.

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Processing aluminum alloys employing powder bed fusion of metals (PBF-LB/M) is becoming more attractive for the industry, especially if lightweight applications are needed. Unfortunately, high-strength aluminum alloys such as AA7075 are prone to hot cracking during PBF-LB/M, as well as welding. Both a large solidification range promoted by the alloying elements zinc and copper and a high thermal gradient accompanied with the manufacturing process conditions lead to or favor hot cracking. In the present study, a simple method for modifying the powder surface with titanium carbide nanoparticles (NPs) as a nucleating agent is aimed. The effect on the microstructure with different amounts of the nucleating agent is shown. For the aluminum alloy 7075 with 2.5 ma% titanium carbide nanoparticles, manufactured via PBF-LB/M, crack-free samples with a refined microstructure having no discernible melt pool boundaries and columnar grains are observed. After using a two-step ageing heat treatment, ultimate tensile strengths up to 465 MPa and an 8.9% elongation at break are achieved. Furthermore, it is demonstrated that not all nanoparticles used remain in the melt pool during PBF-LB/M.
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Martucci, Alessandra, Alberta Aversa, and Mariangela Lombardi. "Ongoing Challenges of Laser-Based Powder Bed Fusion Processing of Al Alloys and Potential Solutions from the Literature—A Review." Materials 16, no. 3 (January 26, 2023): 1084. http://dx.doi.org/10.3390/ma16031084.

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Their high strength-to-weight ratio, good corrosion resistance and excellent thermal and electrical conductivity have exponentially increased the interest in aluminium alloys in the context of laser-based powder bed fusion (PBF-LB/M) production. Although Al-based alloys are the third most investigated category of alloys in the literature and the second most used in industry, their processing by PBF-LB/M is often hampered by their considerable solidification shrinkage, tendency to oxidation, high laser reflectivity and poor powder flowability. For these reasons, high-strength Al-based alloys traditionally processed by conventional procedures have often proved to be unprintable with additive technology, so the design and development of new tailored Al-based alloys for PBF-LB/M production is necessary. The aim of the present work is to explore all the challenges encountered before, during and after the PBF-LB/M processing of Al-based alloys, in order to critically analyse the solutions proposed in the literature and suggest new approaches for addressing unsolved problems. The analysis covers the critical aspects in the literature as well as industrial needs, industrial patents published to date and possible future developments in the additive market.
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Huber, Florian, Dominic Bartels, and Michael Schmidt. "In-Situ Alloy Formation of a WMoTaNbV Refractory Metal High Entropy Alloy by Laser Powder Bed Fusion (PBF-LB/M)." Materials 14, no. 11 (June 4, 2021): 3095. http://dx.doi.org/10.3390/ma14113095.

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High entropy or multi principal element alloys are a promising and relatively young concept for designing alloys. The idea of creating alloys without a single main alloying element opens up a wide space for possible new alloy compositions. High entropy alloys based on refractory metals such as W, Mo, Ta or Nb are of interest for future high temperature applications e.g., in the aerospace or chemical industry. However, producing refractory metal high entropy alloys by conventional metallurgical methods remains challenging. For this reason, the feasibility of laser-based additive manufacturing of the refractory metal high entropy alloy W20Mo20Ta20Nb20V20 by laser powder bed fusion (PBF-LB/M) is investigated in the present work. In-situ alloy formation from mixtures of easily available elemental powders is employed to avoid an expensive atomization of pre-alloyed powder. It is shown that PBF-LB/M of W20Mo20Ta20Nb20V20 is in general possible and that a complete fusion of the powder mixture without a significant number of undissolved particles is achievable by in-situ alloy formation during PBF-LB/M when selecting favorable process parameter combinations. The relative density of the samples with a dimension of 6 × 6 × 6 mm3 reaches, in dependence of the PBF-LB/M parameter set, 99.8%. Electron backscatter diffraction (EBSD) and transmission electron microscopy (TEM) measurements confirm the presence of a single bcc-phase. Scanning electron microscopy (SEM) images show a dendritic and/or cellular microstructure that can, to some extent, be controlled by the PBF-LB/M parameters.
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Kessler, Olaf, Evgeny Zhuravlev, Sigurd Wenner, Steffen Heiland, and Mirko Schaper. "Correlation between Differential Fast Scanning Calorimetry and Additive Manufacturing Results of Aluminium Alloys." Materials 15, no. 20 (October 15, 2022): 7195. http://dx.doi.org/10.3390/ma15207195.

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High-strength aluminium alloy powders modified with different nanoparticles by ball milling (7075/TiC, 2024/CaB6, 6061/YSZ) have been investigated in-situ during rapid solidification by differential fast scanning calorimetry (DFSC). Solidification undercooling has been evaluated and was found to decrease with an increasing number of nanoparticles, as the particles act as nuclei for solidification. Lower solidification undercooling of individual powder particles correlates with less hot cracking and smaller grains in the material produced by powder bed fusion of metals by a laser beam (PBF-LB/M). Quantitatively, solidification undercooling less than about 10–15 K correlates with almost crack-free PBF-LB/M components and grain sizes less than about 3 µm. This correlation shall be used for future purposeful powder material design on small quantities before performing extensive PBF-LB/M studies.
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Wimmer, Andreas, Baturay Yalvac, Christopher Zoeller, Fabian Hofstaetter, Stefan Adami, Nikolaus A. Adams, and Michael F. Zaeh. "Experimental and Numerical Investigations of In Situ Alloying during Powder Bed Fusion of Metals Using a Laser Beam." Metals 11, no. 11 (November 16, 2021): 1842. http://dx.doi.org/10.3390/met11111842.

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Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) is increasingly utilized for the fabrication of complex parts in various industrial sectors. Enabling a robust and reproducible manufacturing process is one of the main goals in view of the future success of PBF-LB/M. To meet these challenges, alloys that are specifically adapted to the process are required. This paper demonstrates the successful interplay of simulation studies with experimental data to analyze the basic phenomena of in situ alloying. The meshless Smoothed-Particle Hydrodynamics (SPH) method was employed for the numerical simulation of two-component powder systems considering both thermodynamics and fluid mechanics in the solid and the melt phase. The simulation results for the in situ alloying of stainless steel 316L blended with the aluminum alloy AlSi10Mg were enriched and validated with the data from a novel experimental test bench. The combination of both approaches can enhance the understanding of the process for in situ alloying. Therefore, future investigations of the PBF-LB/M process with multi-component powder systems can benefit from detailed numerical studies using SPH.
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Wimmer, Andreas, Fabian Hofstaetter, Constantin Jugert, Katrin Wudy, and Michael F. Zaeh. "In situ alloying: investigation of the melt pool stability during powder bed fusion of metals using a laser beam in a novel experimental set-up." Progress in Additive Manufacturing 7, no. 2 (October 31, 2021): 351–59. http://dx.doi.org/10.1007/s40964-021-00233-y.

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AbstractThe limited access to materials for the Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) is compensated by in situ alloying. Individual melt pool characteristics can be specifically influenced to improve the mechanical properties of the final part. However, conventional PBF-LB/M machines allow only limited access for detailed observation of the process zone and, in particular, the melt pool. This paper presents a methodology for systematically analyzing the melt pool in the cross section to determine the in situ variation of the melt pool depth. A custom PBF-LB/M test bench was devised to enable investigation of the process zone using high-speed infrared cameras. The image data were processed automatically using a dedicated algorithm. The methodology was applied to analyze the effect of additives on the melt pool stability. Stainless steel 316L powder was blended with the aluminum alloy AlSi10Mg by up to 20 wt.%. It was found that the blended powder significantly reduced the variation of the melt pool depth.
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Schmitt, Matthias, Albin Gottwalt, Jakob Winkler, Thomas Tobie, Georg Schlick, Karsten Stahl, Ulrich Tetzlaff, Johannes Schilp, and Gunther Reinhart. "Carbon Particle In-Situ Alloying of the Case-Hardening Steel 16MnCr5 in Laser Powder Bed Fusion." Metals 11, no. 6 (May 31, 2021): 896. http://dx.doi.org/10.3390/met11060896.

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The carbon content of steel affects many of its essential properties, e.g., hardness and mechanical strength. In the powder bed fusion process of metals using a laser beam (PBF-LB/M), usually, pre-alloyed metal powder is solidified layer-by-layer using a laser beam to create parts. A reduction of the carbon content in steels is observed during this process. This study examines adding carbon particles to the metal powder and in situ alloying in the PBF-LB/M process as a countermeasure. Suitable carbon particles are selected and their effect on the particle size distribution and homogeneity of the mixtures is analysed. The workability in PBF-LB is then shown. This is followed by an evaluation of the resulting mechanical properties (hardness and mechanical strength) and microstructure in the as-built state and the state after heat treatment. Furthermore, potential use cases like multi-material or functionally graded parts are discussed.
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Huber, Florian, Michael Rasch, and Michael Schmidt. "Laser Powder Bed Fusion (PBF-LB/M) Process Strategies for In-Situ Alloy Formation with High-Melting Elements." Metals 11, no. 2 (February 16, 2021): 336. http://dx.doi.org/10.3390/met11020336.

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In-situ alloy formation by Laser Powder Bed Fusion (PBF-LB/M) from mixtures of easily available elemental powders is an appealing approach for developing and qualifying new alloys for laser based additive manufacturing of metals. However, especially when dealing with high-melting elements, like W, Ta, Mo, or Nb, it is difficult to achieve a homogeneous element distribution and a complete fusion of the powder particles. The aim of this work was to understand the effects of the PBF-LB/M process parameters (laser power, scan speed, laser spot diameter) and three different single- and double-exposure strategies on the fusion of high-melting W, Ta, Mo, and Nb particles in a Ti-matrix. For this purpose, 220 samples with 10 vol.% of the high-melting particle fraction were prepared and analyzed by optical light microscopy and automated image processing, as well as by scanning electron microscopy (SEM). The results are discussed in the context of current research on the process dynamics of PBF-LB/M. Based on that process strategies to support a complete fusion of high-melting particles during in-situ alloy formation are derived. It is shown that the number of unmolten particles can be at least decreased by a factor of ten compared to the most unfavorable parameter combination. For the lower melting elements, Nb and Mo, a complete fusion without any remaining particles visible in the microsections was achieved for certain parameter combinations. The results prove the feasibility of in-situ alloy formation with high-melting alloying elements, but they also demonstrate the necessity to adjust the PBF-LB/M process strategy to achieve a complete dissolution of the alloying elements.
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Bartsch, K., and C. Emmelmann. "Enabling Cost-Based Support Structure Optimization in Laser Powder Bed Fusion of Metals." JOM 74, no. 3 (December 16, 2021): 1126–35. http://dx.doi.org/10.1007/s11837-021-05055-5.

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AbstractSupport structures are essential to laser powder bed fusion (PBF-LB/M). They sustain overhangs, prevent distortion, and dissipate process-induced heat. Their removal after manufacturing is required, though, increasing the overall costs. Therefore, optimization is important to increase the economic efficiency of PBF-LB/M. To enable optimization focused on the support structures’ costs, a cost model is developed. The whole production process, including the design, manufacturing, and post-processing of a part, is considered by deriving formulas for the individual costs. The cost model is applied to a previously developed benchmark procedure. Additionally, a case study investigating different support layout strategies is conducted.
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Dissertations / Theses on the topic "PBF-LB/M"

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Sevastopolev, Ruslan. "Effect of conformal cooling in Additive Manufactured inserts on properties of high pressure die cast aluminum component." Thesis, 2020. http://urn.kb.se/resolve?urn=urn:nbn:se:hj:diva-50949.

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Additive manufacturing can bring several advantages in tooling applications especially hot working tooling as high pressure die casting. Printing of conformal cooling channels can lead to improved cooling and faster solidification, which, in turn, can possibly result in better quality of the cast part. However, few studies on advantages of additive manufactured tools in high pressure die casting are published.The aim of this study was to investigate and quantify the effect of conformal cooling on microstructure and mechanical properties of high pressure die cast aluminum alloy. Two tools each consisting of two die inserts were produced with and without conformal channels using additive manufacturing. Both tools were used in die casting of aluminum alloy. Aluminum specimens were then characterized microstructurally in light optical microscope for secondary arm spacing measurements and subjected to tensile and hardness testing. Cooling behavior of different inserts was studied with a thermal camera and by monitoring the temperature change of cooling oil during casting. Surface roughness of die inserts was measured with profilometer before and after casting.Thermal imaging of temperature as a function of time and temperature change of oil during casting cycle indicated that conformal insert had faster cooling and lower temperature compared to conventional insert. However, thermal imaging of temperature after each shot in a certain point of time showed higher maximum and minimum temperature on conformal die surface but no significant difference in normalized temperature gradient compared to the conventional insert.The average secondary dendrite arm spacing values were fairly similar for samples from conventional and conformal inserts, while more specimens from conventional insert demonstrated coarser structure. Slower cooling in conventional insert could result in the coarser secondary dendrite arm spacing.Tensile strength and hardness testing revealed no significant difference in mechanical properties of the specimens cast in conventional and conformal die inserts. However, reduced deviations in hardness was observed for samples cast with conformal insert. This is in agreement with secondary dendrite arm spacing measurements indicating improved cooling with conformal insert.Surface roughness measurement showed small wear of the inserts. More castings are needed to observe a possible difference in wear between the conventional and conformal inserts.Small observed differences in cooling rate and secondary arm spacing did not result in evident difference in mechanical properties of the aluminum alloy but the variation in properties were reduced for samples cast with conformal cooling. Future work may include more accurate measurement of cooling behavior with a thermocouple printed into the die insert, casting of thicker specimen for porosity evaluation and fatigue testing and longer casting series to evaluate the influence of conformal cooling on tool wear.
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Book chapters on the topic "PBF-LB/M"

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Meiners, Wilhelm, S. Heer, J. Volkert, F. Schaede, and P. Wagenblast. "Methodik zur Quantifizierung der Laserstrahl-Schmauch Interaktion in Multilaser PBF-LB/M Anlagen." In Proceedings of the 17th Rapid.Tech 3D Conference Erfurt, Germany, 22–23 June 2021, 67–79. München: Carl Hanser Verlag GmbH & Co. KG, 2021. http://dx.doi.org/10.3139/9783446471733.005.

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Winkler, Karl Jakob, Matthias Schmitt, Thomas Tobie, Georg Schlick, Karsten Stahl, and Rüdiger Daub. "Characterization and Influences of the Load Carrying Capacity of Lightweight Hub Designs of 3D-Printed Gears (16MnCr5, PBF-LB/M-Process)." In Proceedings of the Munich Symposium on Lightweight Design 2021, 160–74. Berlin, Heidelberg: Springer Berlin Heidelberg, 2022. http://dx.doi.org/10.1007/978-3-662-65216-9_15.

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Conference papers on the topic "PBF-LB/M"

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Feng, Shaw C., Yan Lu, and Albert T. Jones. "Measured Data Alignments for Monitoring Metal Additive Manufacturing Processes Using Laser Powder Bed Fusion Methods." In ASME 2020 International Design Engineering Technical Conferences and Computers and Information in Engineering Conference. American Society of Mechanical Engineers, 2020. http://dx.doi.org/10.1115/detc2020-22478.

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Abstract The number and types of measurement devices used for monitoring and controlling Laser-Based Powder Bed Fusion of Metals (PBF-LB/M) processes and inspecting the resulting AM metal parts have increased rapidly in recent years. The variety of the data collected by such devices has increased, and the veracity of the data has decreased simultaneously. Each measurement device generates data in a unique coordinate system and in a unique data type. Data alignment, however, is required before 1) monitoring and controlling PBF-LB/M processes, 2) predicting the material properties of the final part, and 3) qualifying the resulting AM parts can be done. Aligned means all data must be transformed into a single coordinate system. In this paper, we describe a new, general data-alignment procedure and an example based on PBF-LB/M processes. The specific data objects used in this example include in-situ photogrammetry, thermography, ex-situ X-ray computed tomography (XCT), coordinate metrology, and computer-aided design (CAD) models. We propose a data-alignment procedure to align the data from melt pool images, scan paths, layer images, XCT three-dimensional (3D) model, coordinate measurements, and the 3D CAD model.
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Schmelter, Tobias, Benedict Theren, Magnus Thiele, Marvin Schuleit, Cemal Esen, and Bernd Kuhlenkötter. "Integration of SMA Wires Into the Additive Manufacturing Process Using PBF-LB/M and Long-Term Tests of the Specimens to Validate the Functional Properties." In ASME 2021 Conference on Smart Materials, Adaptive Structures and Intelligent Systems. American Society of Mechanical Engineers, 2021. http://dx.doi.org/10.1115/smasis2021-67650.

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Abstract The integration of shape memory (SM) wires in additive manufacturing (AM) processes and components, either as actuators or sensors, holds enormous potential for future developments. For example, a sensor or an actuator function could be integrated into a component already during the manufacturing process. This integration can eliminate downstream assembly steps and improve the flexibility of the component design. In addition to (complex) components, the AM process can also be used to attach connecting elements to the wire, ensuring an improved connection of the wire to other components like an actuator housing. The integration of SM wires into an AM process will be further investigated in the following and feasibility validated by initial trials. Powder bed fusion – laser beam/metal (PBF-LB/M) is used as an AM process; thereby blocks are welded to the wire in the context of this work as proof of concept. Long-term and tensile tests are carried out to evaluate the functional and mechanical properties of the manufactured compounds. Moreover, images of a scanning electron microscope (SEM) in combination with energy dispersive X-ray spectroscopy (EDX) provide further information about the generated compound.
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