Ultrasonic material dispensing-based selective laser melting for 3D printing of metallic components and the effect of powder compression

Chao Wei; Heng Gu; Zhe Sun; Dongxu Cheng; Yuan-hui Chueh; Xiaoji Zhang; Yihe Huang; Lin Li

doi:10.1016/j.addma.2019.100818

Ultrasonic material dispensing-based selective laser melting for 3D printing of metallic components and the effect of powder compression

Chao Wei, Heng Gu, Zhe Sun, Dongxu Cheng, Yuan-hui Chueh, Xiaoji Zhang, Yihe Huang, Lin Li

Research output: Contribution to journal › Article › peer-review

Abstract

Selective laser melting (SLM) is one of the most commonly used metallic component 3D printing techniques. In a previous investigation of multiple materials SLM reported by The University of Manchester, high porosities and cracks were found in the regions where the powder was deposited via an ultrasonic powder dispenser. The low powder packing density was identified as a critical reason for this. In this paper, we report a new method to compress the ultrasonically deposited powder layer in order to increase the powder packing density. The effects of powder deposition velocity, powder track overlap distance and powder compression force on the deposited powder characteristics were investigated. The microstructure, tensile strengths, and porosity of the laser-fused samples were analyzed. The results indicated that powder compression could reduce porosity and component distortion and increase the mechanical strength of the printed parts.

Original language	English
Pages (from-to)	100818
Journal	Additive Manufacturing
Volume	29
Early online date	8 Aug 2019
DOIs	https://doi.org/10.1016/j.addma.2019.100818
Publication status	Published - 1 Oct 2019

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10.1016/j.addma.2019.100818

LPRC: Laser Processing Research Centre Impact
Allegre, O. (PI), Crosby, D. (PI), Domingos, M. (PI), Francis, J. (PI), Gillen, D. (PI), Guo, W. (PI), Li, L. (PI), Mativenga, P. (PI), Rogers, B. D. (PI), Whitehead, D. (PI), Wilson, D. (PI), Zhong, S. (PI), Mirhosseini, N. (Researcher), Ouyang, J. (Researcher), Huang, Y. (Researcher), Wei, C. (Researcher), Cheng, D. (PGR student), Suryo Pratomo, E. (PGR student), Zhang, Z. (PGR student), Li, Z. (PGR student), Mo, H. (PGR student), Zhu, M. (PGR student), Li, Q. (PGR student), Liu, W. (PGR student), Wang, L. (PGR student), Guo, H. (PGR student), Heinemann, R. (PI) & Liu, Z. (PI)
1/04/00 → …
Project: Research

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title = "Ultrasonic material dispensing-based selective laser melting for 3D printing of metallic components and the effect of powder compression",

abstract = "Selective laser melting (SLM) is one of the most commonly used metallic component 3D printing techniques. In a previous investigation of multiple materials SLM reported by The University of Manchester, high porosities and cracks were found in the regions where the powder was deposited via an ultrasonic powder dispenser. The low powder packing density was identified as a critical reason for this. In this paper, we report a new method to compress the ultrasonically deposited powder layer in order to increase the powder packing density. The effects of powder deposition velocity, powder track overlap distance and powder compression force on the deposited powder characteristics were investigated. The microstructure, tensile strengths, and porosity of the laser-fused samples were analyzed. The results indicated that powder compression could reduce porosity and component distortion and increase the mechanical strength of the printed parts.",

author = "Chao Wei and Heng Gu and Zhe Sun and Dongxu Cheng and Yuan-hui Chueh and Xiaoji Zhang and Yihe Huang and Lin Li",

year = "2019",

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doi = "10.1016/j.addma.2019.100818",

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journal = "Additive Manufacturing",

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T1 - Ultrasonic material dispensing-based selective laser melting for 3D printing of metallic components and the effect of powder compression

AU - Wei, Chao

AU - Gu, Heng

AU - Sun, Zhe

AU - Cheng, Dongxu

AU - Chueh, Yuan-hui

AU - Zhang, Xiaoji

AU - Huang, Yihe

AU - Li, Lin

PY - 2019/10/1

Y1 - 2019/10/1

N2 - Selective laser melting (SLM) is one of the most commonly used metallic component 3D printing techniques. In a previous investigation of multiple materials SLM reported by The University of Manchester, high porosities and cracks were found in the regions where the powder was deposited via an ultrasonic powder dispenser. The low powder packing density was identified as a critical reason for this. In this paper, we report a new method to compress the ultrasonically deposited powder layer in order to increase the powder packing density. The effects of powder deposition velocity, powder track overlap distance and powder compression force on the deposited powder characteristics were investigated. The microstructure, tensile strengths, and porosity of the laser-fused samples were analyzed. The results indicated that powder compression could reduce porosity and component distortion and increase the mechanical strength of the printed parts.

AB - Selective laser melting (SLM) is one of the most commonly used metallic component 3D printing techniques. In a previous investigation of multiple materials SLM reported by The University of Manchester, high porosities and cracks were found in the regions where the powder was deposited via an ultrasonic powder dispenser. The low powder packing density was identified as a critical reason for this. In this paper, we report a new method to compress the ultrasonically deposited powder layer in order to increase the powder packing density. The effects of powder deposition velocity, powder track overlap distance and powder compression force on the deposited powder characteristics were investigated. The microstructure, tensile strengths, and porosity of the laser-fused samples were analyzed. The results indicated that powder compression could reduce porosity and component distortion and increase the mechanical strength of the printed parts.

U2 - 10.1016/j.addma.2019.100818

DO - 10.1016/j.addma.2019.100818

M3 - Article

SN - 2214-8604

VL - 29

SP - 100818

JO - Additive Manufacturing

JF - Additive Manufacturing

ER -

Ultrasonic material dispensing-based selective laser melting for 3D printing of metallic components and the effect of powder compression

Abstract

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