期刊
MATERIALS
卷 15, 期 3, 页码 -出版社
MDPI
DOI: 10.3390/ma15030705
关键词
flowability; particle size distribution; additive manufacturing; powder bed fusion
类别
资金
- U.S. Department of Energy (DOE) Office of Science User Facility [DE-AC02-06CH11357]
- Boeing Company through the Center for Aerospace Manufacturing Technology (CAMT) at Missouri University of Science and Technology, the National Science Foundation
- Graduate Assistance in Areas of National Need (GAANN) program of the U.S. Department of Education
This study focuses on the effect of particle size distribution (PSD) on powder flowability and the laser melting process. It was found that PSDs near dense packing ratios significantly reduce flowability and powder beds made of powders with dense packing ratios exhibit larger build height during laser melting.
The powder bed-based additive manufacturing (AM) process contains uncertainties in the powder spreading process and powder bed quality, leading to problems in repeatability and quality of the additively manufactured parts. This work focuses on identifying the uncertainty induced by particle size distribution (PSD) on powder flowability and the laser melting process, using Ti6Al4V as a model material. The flowability test results show that the effect of PSDs on flowability is not linear, rather the PSDs near dense packing ratios cause significant reductions in flowability (indicated by the increase in the avalanche angle and break energy of the powders measured by a revolution powder analyzer). The effects of PSDs on the selective laser melting (SLM) process are identified by using in-situ high-speed X-ray imaging to observe the melt pool dynamics during the melting process. The results show that the powder beds made of powders with dense packing ratios exhibit larger build height during laser melting. The effects of PSD with efficient packing on powder flowability and selective laser melting process revealed in this work are important for understanding process uncertainties induced by feedstock powders and for designing mitigation approaches.
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