Journal
POWDER TECHNOLOGY
Volume 384, Issue -, Pages 211-222Publisher
ELSEVIER
DOI: 10.1016/j.powtec.2021.02.022
Keywords
Spreader geometry; Powder spreading; Additive manufacturing; DEM; Substrate force
Categories
Funding
- Australian Research Council Industrial Transformation Research Hubs Scheme [IH140100035]
- Australian Government
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The powder spreading process involves using different types of spreaders to impact the density and uniformity of powder layer deposition. Blade spreaders with round and inclined surfaces create denser powder layers compared to vertical blades, but exert greater forces on the underlying part. Roller systems lead to sparse and uneven powder layers with small gaps between layers. Size segregation is less severe in blade systems compared to roller systems.
Powder spreading process is to use a spreader such as blade or roller to spread powder layers for subsequent fusion in powder bed fusion additive manufacturing. In this work, the effects of various spreader geometries on powder spreading are examined by discrete element method (DEM). The results show that a compact region in the powder pile exists. Round and inclined surfaces of blade spreaders allow more particles in the compact region to be deposited compared with vertical blades, thus the powder layer formed is denser. However, they exert larger forces on the underlying part. Inhomogeneity of powder layers is caused by particle burst phenomenon, which is due to particle motion conflict in the compact region rather than large forces. Roller system has largest particle motion conflict thus powder layers formed are sparse and inhomogeneous with small layer gaps. Size segregation in blade systems is not as severe as roller systems. (c) 2021 Elsevier B.V. All rights reserved. Powder spreading process is to use a spreader such as blade or roller to spread powder layers for subsequent fusion in powder bed fusion additive manufacturing. In this work, the effects of various spreader geometries on powder spreading are examined by discrete element method (DEM). The results show that a compact region in the powder pile exists. Round and inclined surfaces of blade spreaders allow more particles in the compact region to be deposited compared with vertical blades, thus the powder layer formed is denser. However, they exert larger forces on the underlying part. Inhomogeneity of powder layers is caused by particle burst phenomenon, which is due to particle motion conflict in the compact region rather than large forces. Roller system has largest particle motion conflict thus powder layers formed are sparse and inhomogeneous with small layer gaps. Size segregation in blade systems is not as severe as roller systems.
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