An Experimental Characterization of Powder/Substrate Interaction during Direct Metal Deposition for Additive Manufacturing

Abstract:

The physical behavior of metal powders during laser-based additive manufacturing processes has been investigated. In particular, an experimental campaign of direct metal deposition has been carried out to evaluate the effect of the laser power and spot size on the powder/substrate interaction and on the surface morphology of the final piece. A fast-camera has been used to evaluate the interaction phenomena during the printing process, while confocal microscopy has been carried out to measure the surface morphology of the samples. Results highlighted that increasing the laser power and laser spot size, the particle impact velocity is about constant, while the powder/laser/substrate interaction zone increases. As a consequence, the mean thickness increases, as confirmed by surface characterization.

• Periodical: Key Engineering Materials (Volume 813)
• Pages: 435-440
• DOI: https://doi.org/10.4028/www.scientific.net/KEM.813.435
• Online since: July 2019
• Authors: Maurizio Troiano*, Alessia Teresa Silvestri, Fabio Scherillo, Andrea El Hassanin, Roberto Solimene, Antonino Squillace, Piero Salatino
• Keywords: Additive Manufacturing, Direct Metal Deposition, Powder/Substrate Interaction

References

[1] S.A.M. Tofail, E.P. Koumoulos, A. Bandyopadhyay, S. Bose, L. O'Donoghue, C. Charitidis, Additive manufacturing: scientific and technological challenges, market uptake and opportunities, Mater. Today 21 (2018) 22-37.

DOI: 10.1016/j.mattod.2017.07.001

[2] S. Ford, M. Despeisse, Additive manufacturing and sustainability: an exploratory study of the advantages and challenges, J. Clean Prod. 137 (2016) 1573-1587.

DOI: 10.1016/j.jclepro.2016.04.150

[3] D. Herzog, V. Seyda, E. Wycisk, C. Emmelmann, Additive manufacturing of metals, Acta Mater. 117 (2016) 371-392.

DOI: 10.1016/j.actamat.2016.07.019

[4] S.M. Thompson, L. Bian, N. Shamsaei, A. Yadollahi, An overview of Direct Laser Deposition for additive manufacturing; Part I: Transport phenomena, modeling and diagnostics, Addit. Manuf. 8 (2015) 36-62.

DOI: 10.1016/j.addma.2015.07.001

[5] N. Shamsaei, A. Yadollahi, L. Bian, S.M. Thompson, An overview of Direct Laser Deposition for additive manufacturing; Part II: Mechanical behavior, process parameter optimization and control, Addit. Manuf. 8 (2015) 12-35.

DOI: 10.1016/j.addma.2015.07.002

[6] M.A. Obeidi, E. McCarthy, B. O'Connell, I.U. Ahad, D. Brabazon, Laser polishing of additive manufactured 316L stainless steel synthesized by selective laser melting, Materials 12 (2019) 991.

DOI: 10.3390/ma12060991

[7] M. Troiano, P. Salatino, R. Solimene, F. Montagnaro, Wall effects in entrained particle-laden flows: The role of particle stickiness on solid segregation and build-up of wall deposits, Powder Technol. 266 (2014) 282-291.

DOI: 10.1016/j.powtec.2014.06.039

[8] F. Blateyron, The areal field parameters. In: Leach R, editor. Characterisation of Areal Surface Texture. Berlin Heidelberg: Springer-Verlag, 2013 p.15–43.

DOI: 10.1007/978-3-642-36458-7_2

[9] F. Scherillo, Chemical surface finishing of AlSi10Mg components made by additive manufacturing. Manuf Lett 19 (2019) 5–9.

DOI: 10.1016/j.mfglet.2018.12.002

[10] E. Atzeni, M. Barletta, F. Calignano, L. Iuliano, G. Rubino, V. Tagliaferri, Abrasive Fluidized Bed (AFB) finishing of AlSi10Mg substrates manufactured by Direct Metal Laser Sintering (DMLS), Addit. Manuf. 8 (2016) 15-23.

DOI: 10.1016/j.addma.2016.01.005