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Build Rate Optimization for Powder Bed Fusion

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Abstract

The authors previously proposed a geometrically based model to predict the volume fraction of lack-of-fusion porosity in parts produced by powder bed fusion. To test this model, AlSi10Mg cubes with varying hatch spacing and layer thickness were printed in this work. Bulk densities of samples were measured with the Archimedes method and agree well with model predictions. The model was also validated by results from the literature on additively manufactured PA-12 polymer parts. Quantitative prediction of conditions that lead to part porosity allows considerable improvement in the volumetric build rate, compared with the default processing parameters provided by the equipment supplier. Nearly fully dense AlSi10Mg parts (> 99.5% dense) were fabricated with a build rate double that for standard conditions. Some melt-pool variability and large changes in hatch rotation angle do not affect the overall volume fraction of residual porosity.

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Acknowledgments

This material is based on research sponsored by Air Force Research Laboratory under agreement number FA8650-12-2-7230 and by the Commonwealth of Pennsylvania, acting through the Department of Community and Economic Development, under Contract Number C000053981. The US Government is authorized to reproduce and distribute reprints for Governmental purposes notwithstanding any copyright notation thereon. Any opinions, views, findings, recommendations, and conclusions contained herein are those of the authors and should not be interpreted as necessarily representing the official policies or endorsements, either expressed or implied, of the Air Force Research Laboratory, the US Government, the Commonwealth of Pennsylvania, Carnegie Mellon University, or Lehigh University. The authors acknowledge use of the Materials Characterization Facility at Carnegie Mellon University supported by Grant MCF-677785. The assistance and support of Arconic are gratefully acknowledged.

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Authors and Affiliations

  1. Department of Materials Science and Engineering, Carnegie Mellon University, 5000 Forbes Avenue, Pittsburgh, PA, 15213, USA

    Ming Tang & Petrus Christiaan Pistorius

  2. Department of Mechanical Engineering, Carnegie Mellon University, 5000 Forbes Avenue, Pittsburgh, PA, 15213, USA

    Colt Montgomery & Jack Beuth

  3. NextManufacturing Center, Carnegie Mellon University, 5000 Forbes Avenue, Pittsburgh, PA, 15213, USA

    Petrus Christiaan Pistorius & Jack Beuth

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  1. Ming Tang
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  2. Petrus Christiaan Pistorius
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  3. Colt Montgomery
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  4. Jack Beuth
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Corresponding author

Correspondence to Petrus Christiaan Pistorius.

Additional information

This article is an invited paper selected from presentations at the symposium “Additive Manufacturing of Metals: Microstructure and Material Properties,” held during MS&T’17, October 8-12, 2017, in Pittsburgh, Pa., and has been expanded from the original presentation.

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Tang, M., Pistorius, P.C., Montgomery, C. et al. Build Rate Optimization for Powder Bed Fusion. J. of Materi Eng and Perform 28, 641–647 (2019). https://doi.org/10.1007/s11665-018-3647-5

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  • DOI: https://doi.org/10.1007/s11665-018-3647-5

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