This page has only limited features, please log in for full access.
Research and development in the field of metal-based additive manufacturing are advancing steadily every year. In order to increase the efficiency of powder bed fusion of metals using a laser beam system (PBF LB/M), machine manufacturers have implemented extensive optimizations with regard to the laser systems and build volumes. However, the optimization of metallic powder materials using nanoparticle additives enables an additional improvement of the laser–material interaction. In this work, tool steel 1.2709 powder was coated with silicon carbide (SiC), few-layer graphene (FLG), and iron oxide black (IOB) on a nanometer scale. Subsequently, the feedstock material and the modified powder materials were analyzed concerning the reflectance of the laser radiation and processed by PBF-LB/M in a systematic and consistent procedure to evaluate the impact of the nano-additivation on the process efficiency and mechanical properties. As a result, an increased build rate is achieved, exhibiting a relative density of 99.9% for FLG/1.2709 due to a decreased reflectance of this modified powder material. Furthermore, FLG/1.2709 provides hardness values after precipitation hardening with only aging comparable to the original 1.2709 material and is higher than the SiC- and IOB-coated material. Additionally, the IOB coating tends to promote oxide-formation and lack-of-fusion defects.
Oliver Pannitz; Felix Großwendt; Arne Lüddecke; Arno Kwade; Arne Röttger; Jan Sehrt. Improved Process Efficiency in Laser-Based Powder Bed Fusion of Nanoparticle Coated Maraging Tool Steel Powder. Materials 2021, 14, 3465 .
AMA StyleOliver Pannitz, Felix Großwendt, Arne Lüddecke, Arno Kwade, Arne Röttger, Jan Sehrt. Improved Process Efficiency in Laser-Based Powder Bed Fusion of Nanoparticle Coated Maraging Tool Steel Powder. Materials. 2021; 14 (13):3465.
Chicago/Turabian StyleOliver Pannitz; Felix Großwendt; Arne Lüddecke; Arno Kwade; Arne Röttger; Jan Sehrt. 2021. "Improved Process Efficiency in Laser-Based Powder Bed Fusion of Nanoparticle Coated Maraging Tool Steel Powder." Materials 14, no. 13: 3465.
One of the AM processes for direct manufacturing of metallic components is powder bed fusion of metals using a laser beam system (PBF-LB/M), in which metallic powders are molten and solidified in a layer upon layer manner by a focused laser beam. In recent years, the focus has initially been on increasing the efficiency of the systems itself. However, the modification of standard AM metal alloys using nanoparticles offers the possibility to improve the PBF-LB/M-process concerning its process efficiency and actual densification and thermal conductivity. In this work, a methodology for an in-situ investigation of the thermal conductivity as well as the reflectance behavior of metallic powder materials during the PBF-LB/M-process is established. The powder material stainless steel 1.4404 was coated with different nanoparticles (few-layer graphene (FLG), silicon carbide (SiC)) and processed in a standardized build process. As a result, the reflectance rate of all modified materials could be increased. Besides, the thermal conductivity of the material is attested to be a decisive and influencing factor for the quality of the final component. Thus, an improved relative density was achieved using the FLG/1.4404 and SiC/1.4404 (1 vol%) due to the increased thermal conductivity of the material. Also significant defects in the cross section were visible at SiC/1.4404 (4 vol%).
O. Pannitz; A. Lüddecke; A. Kwade; J.T. Sehrt. Investigation of the in situ thermal conductivity and absorption behavior of nanocomposite powder materials in laser powder bed fusion processes. Materials & Design 2021, 201, 109530 .
AMA StyleO. Pannitz, A. Lüddecke, A. Kwade, J.T. Sehrt. Investigation of the in situ thermal conductivity and absorption behavior of nanocomposite powder materials in laser powder bed fusion processes. Materials & Design. 2021; 201 ():109530.
Chicago/Turabian StyleO. Pannitz; A. Lüddecke; A. Kwade; J.T. Sehrt. 2021. "Investigation of the in situ thermal conductivity and absorption behavior of nanocomposite powder materials in laser powder bed fusion processes." Materials & Design 201, no. : 109530.
In the past decade, the sales of metal additive manufacturing systems have increased intensely. In particular, PBF-LB/M systems (powder bed fusion of metals using a laser-based system) represent a technology of great industrial interest, in which metallic powders are molten and solidified layer upon layer by a focused laser beam. This leads to a simultaneous increase in demand for metallic powder materials. Due to adjusted process parameters of PBF-LB/M systems, the powder is usually procured by the system’s manufacturer. The requirement and freedom to process different feedstocks in a reproducible quality and the economic and ecological factors involved are reasons to have a closer look at the differences between the quality of the provided metallic powders. Besides, different feedstock materials require different energy inputs, allowing a sustainable process control to be established. In this work, powder quality of stainless steel 1.4404 and the effects during the processing of metallic powders that are nominally the same were analyzed and the influence on the build process followed by the final part quality was investigated. Thus, a correlation between morphology, particle size distribution, absorptivity, flowability, and densification depending on process parameters was demonstrated. Optimized exposure parameters to ensure a more sustainable and energy and cost-efficient manufacturing process were determined.
Oliver Pannitz; Jan T. Sehrt. Transferability of Process Parameters in Laser Powder Bed Fusion Processes for an Energy and Cost Efficient Manufacturing. Sustainability 2020, 12, 1565 .
AMA StyleOliver Pannitz, Jan T. Sehrt. Transferability of Process Parameters in Laser Powder Bed Fusion Processes for an Energy and Cost Efficient Manufacturing. Sustainability. 2020; 12 (4):1565.
Chicago/Turabian StyleOliver Pannitz; Jan T. Sehrt. 2020. "Transferability of Process Parameters in Laser Powder Bed Fusion Processes for an Energy and Cost Efficient Manufacturing." Sustainability 12, no. 4: 1565.