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Multi-Laser Powder Bed Fusion Benchmarking—Initial Trials with Inconel 625
摘要： Production rate is an increasingly important factor in the deployment of metal additive manufacturing (AM) throughout industry. To address the perceived low production rate of metal AM systems based on single-laser powder bed fusion (L-PBF), several companies now offer systems in which melting has been parallelised by the introduction of multiple, independently controlled laser beams. Nevertheless, a full set of studies is yet to be conducted to benchmark the efficiency of multi-laser systems and, at the same time, to verify if the mechanical properties of components are compromised due to the increase in build rate. This study addresses the described technology gaps and presents a 4-beam L-PBF system operating in “single multi” (SM) mode (SM-L-PBF) where each of the four lasers is controlled so that it melts all of a particular components’ layers and produces specimens for comparison with standard L-PBF specimens from the same machine. That is all four lasers making all of some of the parts were compared to a single-laser manufacturing all of the parts. Build parameters were kept constant throughout the manufacturing process and the material used was Inconel 625 (IN625). Stress-relieving heat treatment was conducted on As-built (AB) specimens. Both AB and heat-treated (HT) specimen sets were tested for density, microstructure, tensile strength and hardness. Results indicate that the stress-relieving heat treatment increases specimen ductility without compromising other mechanical properties. SM-L-PBF has achieved a build rate of 14 cm3/h when four 200 W lasers were used to process IN625 at a layer thickness of 30 μm. An increase in the build rate of 2.74 times (build time reduction: 63%) has been demonstrated when compared to that of L-PBF, with little to no compromises in specimen mechanical properties. The observed tensile properties exceed the American Society for Testing Materials (ASTM) requirements for IN625 (by a margin of 22 to 26% in the 0.2% offset yield strength). Average specimen hardness and grain size are in the same order as that reported in literatures. The study has demonstrated that a multi-laser AM system opens up opportunities to tackle the impasse of low build rate in L-PBF in an industrial setting and that at least when operating in single mode there is no detectable degradation in the mechanical and crystallographic characteristics of the components produced.
关键词： Multi-laser powder bed fusion,Inconel 625,Selective laser melting,Additive manufacturing,Mechanical properties
更新于2025-09-12 10:27:22
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Construction of Cellular Substructure in Laser Powder Bed Fusion
摘要： Cellular substructure has been widely observed in the sample fabricated by laser powder bed fusion, while its growth direction and the crystallographic orientation have seldom been studied. This research tries to build a general model to construct the substructure from its two-dimensional morphology. All the three Bunge Euler angles to specify a unique growth direction are determined, and the crystallographic orientation corresponding to the growth direction is also obtained. Based on the crystallographic orientation, the substructure in the single track of austenitic stainless steel 316L is distinguished between the cell-like dendrite and the cell. It is found that, with the increase of scanning velocity, the substructure transits from cell-like dendrite to cell. When the power is 200 W, the critical growth rate of the transition in the single track can be around 0.31 ms?1.
关键词： cell,cell-like dendrite,crystallographic orientation,model,laser powder bed fusion,substructure,growth direction
更新于2025-09-12 10:27:22
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Influence of laser post-processing on pore evolution of Ti–6Al–4V alloy by laser powder bed fusion
摘要： In laser powder bed fusion (LPBF) processes, critical defect issues such as porosity limit the quality of the fabricated part. This work investigates the mechanism of pore evolution during the laser post-processing of an LPBF part. A laser beam was utilized to scan the top surface of a Ti–6Al–4V alloy part. The morphologies of the internal layers as well as the distribution of the porosity inside the Ti–6Al–4V sample were experimentally measured and compared using micro-computed tomography (micro-CT). It was found that the void fraction was significantly decreased, from 2.51% to 0.77%, by laser post-processing. A multi-physics coupled finite element model based on the Level-set method was built to analyze the evolution mechanism of the pore. This model simulated the effects of the energy density, Marangoni flow and mass transfer on the pore evolution. Typical processes were studied in detail, and a table summarizing the pore evolution under different post-processing parameters is given.
关键词： Ti–6Al–4V alloy,Laser powder bed fusion,Pore evolution,Additive manufacturing,Level-set method
更新于2025-09-12 10:27:22
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Accurate Determination of Laser Spot Position during Laser Powder Bed Fusion Process Thermography
摘要： High-speed thermography is useful tool for researching the laser powder bed fusion process by providing thermal information in heat affected zone. However, it is not directly possible to ascertain the position of the laser spot with respect to the melt pool, which could provide key information regarding how laser energy is distributed and absorbed. In this paper, we demonstrate a procedure for registering the laser spot position with the melt pool using a bright illumination source co-axially aligned with the laser to project a sharp spot on the build plane. This spot is fixed to the laser position and used as a reference frame for registering the laser spot with the melt pool radiance temperature distribution. Measurement results demonstrate the effect of varying process parameters (laser power and scan speed) on the melt pool thermal field and respective position of the laser spot.
关键词： additive manufacturing,Laser powder bed fusion,thermography
更新于2025-09-12 10:27:22
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Rapid Solidification and Non-equilibrium Phase Constitution in Laser Powder Bed Fusion (LPBF) of AlSi10Mg Alloy: Analysis of Nano-precipitates, Eutectic Phases, and Hardness Evolution
摘要： The non-equilibrium phase evolution during laser powder bed fusion (LPBF) of AlSi10Mg alloy is thoroughly characterized and analyzed by means of advanced electron microscopy and analytical simulation of rapid solidification phenomenon. The evolution of microstructural strengthening agents such as inter-cellular eutectic phase and intra-cellular precipitates is presented in correspondence with the local variation of cellular/dendritic solidification patterns within a typical melt pool. The eutectic phase exhibits two different morphologies: lamellar and fibrous. As with the cell size variation, the overall volume fraction of eutectic phase and the lamella spacing is shown to gradually decrease by moving away from the melt-pool boundary (MPB), i.e., through crossing over from a coarse to a fine cellular zone. The eutectic-free regions within the a-Al cells contain a large number density of nano-sized precipitates that are predominantly Si-rich and are either fully or semi-coherent with the Al matrix. The formation of nano-precipitates is linked to the increased (non-equilibrium) solubility limits of a-Al cells due to the rapid solidification effect. For the first time, we identify such nano-precipitates with non-equilibrium crystal structures and morphologies: ‘‘Spheres’’ and ‘‘Ellipsoids’’ with Face Centered Cubic (FCC), and ‘‘Plates’’ and ‘‘Needles’’ with a Diamond Cubic (DC) superlattice structure that emerges from within the Al matrix. The microstructure in the heat-affected zone (HAZ) right underneath the MPB exhibits an absence of cell boundaries and eutectic phases while consisting primarily of large Si-rich and Mg-rich precipitates. Finally, the local variation of nano-hardness across a solidified melt pool is shown to correlate well with the corresponding profile of microstructural refinement, i.e., exhibiting a minimum at the HAZ and a peak at around the melt-pool centerline. The findings here can significantly advance the state of knowledge for the strengthening behavior in an as-built LPBF-processed AlSi10Mg alloy.
关键词： hardness evolution,Laser Powder Bed Fusion,non-equilibrium phase evolution,eutectic phases,nano-precipitates,AlSi10Mg
更新于2025-09-12 10:27:22
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Influence of surface topography on fatigue behavior of Ti6Al4V alloy by laser powder bed fusion
摘要： This article deals with the understanding of the influence of surface topography on fatigue behavior of Ti6Al4V alloy specimens produced by laser powder bed fusion (LPBF). The same laser parameters and scan strategy were used for all specimens, giving a sample density higher than 99.5 %. Two different surface topographies were obtained by using the top and side surfaces of the specimens. The surface topography and morphology were investigated by optical surface profilometry and focus variation microscopy. Four-point bending fatigue test was performed on specimens with top and side surfaces as the highest stressed surface respectively. Machined specimens were used as reference. The features of the fracture surface, such as crack initiation and propagation, were analyzed by focus variation and scanning electron microscopy (SEM). Both, fatigue results and fracture surface investigations, were correlated and discussed in relation to surface topography and microstructure, as well as manufacturing parameters.
关键词： laser powder bed fusion,surface topography,Ti6Al4V alloy,fatigue test,fracture mechanisms
更新于2025-09-12 10:27:22
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High-performance microwave waveguide devices produced by laser powder bed fusion process
摘要： Additive manufacturing technologies are currently envisaged to boost the development of a next generation of microwave devices intended for satellite telecommunications. Due to their excellent electromagnetic and mechanical properties, metal waveguide components are key building blocks of several radio frequency (RF) systems used in these applications. This article reports the perspectives deriving from the use of laser powder bed fusion (L-PBF) technology to the production of high-performance microwave waveguide devices. A robust design of filters has been implemented in several prototypes manufactured in AlSi10Mg alloy. The corresponding measured performance confirm the applicability of the L-PBF process to the intended applications
关键词： Additive manufacturing,Antenna-feed systems,Laser powder bed fusion
更新于2025-09-12 10:27:22
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Machining induced residual stresses in AlSi10Mg component produced by Laser Powder Bed Fusion (L-PBF)
摘要： The adoption of metal powder-based laser process (L-PBF) for industrial applications continues to widen, due to an increasing knowledge on additive processes and the availability of new systems for industrial production. The use of L-PBF processes requires a deeper investigation and comparison on mechanical properties of conventional and additive parts. For instance, metal parts produced by L-PBF could require additional machining operations, which alter the stress state of additive components. In this work, the effect of machining operations on the residual stress state of an AlSi10Mg component produced by L-PBF is investigated by means of the semi destructive hole-drilling method.
关键词： AlSi10Mg,Machining,Hole-drilling method,Residual stresses,Laser Powder Bed Fusion
更新于2025-09-12 10:27:22
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Implementation of Advanced Laser Control Strategies for Powder Bed Fusion Systems
摘要： Laser path, scan speed, and laser power are critical machine parameters for determining the quality of the output of laser-based powder bed fusion (LPBF) processes. A jerk-limited control strategy is implemented for laser path planning on a LPBF additive manufacturing (AM) testbed. The actual and commanded laser paths/velocities are found to be in better agreement with each other compared to conventional controls. The new controller enabled implementation of advanced laser power control strategies synchronized with laser position and velocity by embedding all into a modified G-code (referred as AM G-code). An interpreter is developed to utilize sophisticated LPBF laser control commands.
关键词： Jerk-limited Control,Scan Strategies,Laser Powder Bed Fusion Additive Manufacturing (LPBF AM),AM G-code
更新于2025-09-12 10:27:22
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Effect of process parameters on the formation of single track in pulsed laser powder bed fusion
摘要： There has been increasing interest in Laser Powder Bed Fusion (L-PBF) of metallic materials as a promising manufacturing technology. Although most L-PBF systems utilize laser beams with continuous wave emission (L-PBF(CW)), the possibility of using pulsed lasers (L-PBF(P)) has become available in some industrial L-PBF machines over the past few years. Previous studies suggest that the use of pulsed lasers could enable larger control of heat input and melt pool formation during the process, and could thus enable improvement of spatial resolution and feature sizes in L-PBF. In this study, the experiments were implemented using a pulsed laser in combination with continuous scanning movement instead of the ‘point-and-shoot’ method typically used by industrial L-PBF(P) machines of today. The experiments were executed using a trial L-PBF system (IPG ytterbium fiber laser, wavelength 1075 nm) for gas-atomized stainless steel 316L powder on compositionally similar substrates. Single tracks were melted with three different pulse lengths (50, 100, and 200 μs) by using a constant layer thickness of 50 μm, while varying pulse repetition rate, scanning speed and laser power based on six preset values of volume energy density (VED) of 36-120 J/mm3. In order to allow a comparison to be made, additional samples were manufactured by using the CW emission of the same laser. It was observed that the L-PBF(P) samples yielded narrower tracks in comparison to the samples manufactured using CW emission. In addition, the results of the experiments show that, while maintaining constant VED values, decreasing the pulse length or scanning speed decreased the widths of the tracks and their penetration into the substrate. Consequently, it was noticed that shorter pulse lengths require more overlap between consecutive pulses in order to produce continuous tracks. Pulsed emission shows potential for improving the spatial resolution of the L-PBF process.
关键词： Laser powder bed fusion,Single track,Pulsed emission,AISI 316L,Additive manufacturing
更新于2025-09-12 10:27:22