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Effects of powder compression and laser re-melting on the microstructure and mechanical properties of additively manufactured parts in laser-powder bed fusion

Obeidi, Muhannad A. orcid logoORCID: 0000-0003-2733-3828, Conway, Alex, Mussatto, Andre orcid logoORCID: 0000-0001-5335-7968, Doğu, Merve Nur orcid logoORCID: 0000-0003-1843-6040, Sreenilayam, Sithara orcid logoORCID: 0000-0002-5282-3645, Ayub, Hasan, Ahad, Inam Ul orcid logoORCID: 0000-0002-3802-6156 and Brabazon, Dermot orcid logoORCID: 0000-0003-3214-6381 (2022) Effects of powder compression and laser re-melting on the microstructure and mechanical properties of additively manufactured parts in laser-powder bed fusion. Results in Materials, 13 . ISSN 2590-048X

Achieving good surface profile and low levels of porosity are prime challenges in the Laser-Powder Bed Fusion (L-PBF) additive manufacturing technique. In order to optimise these properties, post-processing is often required. However, the compression of powder spread on the build plate and re-melting of each build layer during the L-PBF process could address these challenges. In this study, the effect of different powder compression ratios and laser re-melting regimes on the density, microstructure morphology, surface profile and mechanical properties of L-PBF produced parts were investigated. Two different metal printers with same laser processing parameters were used to fabricate 10 x 10 x 10 mm3 stainless steel 316L samples. To examine the impact of compression ratio and layer re-melting, one set of samples was prepared with three different compression levels for each layer, and the second set of samples either a single or double set of laser passes for each layer. The Volumetric Energy Density (VED) range examines was from 26.7 J/mm3 to 80 J/mm3. Density, hardness, elastic modulus, microstructure, and surface profiles of the printed samples were characterized. A 3% increment in density and a 50% reduction in the surface roughness were achieved using a laser double pass over each layer. The results demonstrate, by applying different powder compression ratios onto the powder bed and by re-melting each layer, that the density, surface roughness, and the elastic modulus of the produced samples can be improved.
Item Type:Article (Published)
Additional Information:Article number: 100264
Uncontrolled Keywords:Laser powder bed fusion; Additive manufacturing; Powder compression; Laser re-melting; Nano-indentation; Archimedes density
Subjects:Engineering > Materials
Engineering > Mechanical engineering
Engineering > Production engineering
DCU Faculties and Centres:DCU Faculties and Schools > Faculty of Engineering and Computing > School of Mechanical and Manufacturing Engineering
Research Institutes and Centres > Advanced Processing Technology Research Centre (APTRC)
Research Institutes and Centres > I-Form
Official URL:https://dx.doi.org/10.1016/j.rinma.2022.100264
Copyright Information:© 2022 Elsevier.
Use License:This item is licensed under a Creative Commons Attribution-NonCommercial-Share Alike 3.0 License. View License
Funders:Science Foundation Ireland (SFI) under grant number 16/RC/3872, European Regional Development Fund
ID Code:26727
Deposited On:04 Mar 2022 11:42 by Sithara Sreenilayam . Last Modified 21 Dec 2023 15:04

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