Optimization of Laser Powder Bed Fusion Processing Using a Combination of Melt Pool Modeling and Design of Experiment Approaches: Density Control

A simplified analytical model of the laser powder bed fusion (LPBF) process was used to develop a novel density prediction approach that can be adapted for any given powder feedstock and LPBF system. First, calibration coupons were built using IN625, Ti64 and Fe powders and a specific LPBF system. T...

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Bibliographic Details
Published inJournal of Manufacturing and Materials Processing Vol. 3; no. 1; p. 21
Main Authors Letenneur, Morgan, Kreitcberg, Alena, Brailovski, Vladimir
Format Journal Article
LanguageEnglish
Published Basel MDPI AG 01.03.2019
Subjects
additive manufacturing
Alloys
analytical model
Calibration
Control algorithms
Density
Design of experiments
Discount coupons
Employment
Heat conductivity
laser powder bed fusion
Lasers
Mathematical models
Mechanical properties
Melting
Optimization
Powder beds
process optimization
Thickness
Titanium base alloys
Germany
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Summary:A simplified analytical model of the laser powder bed fusion (LPBF) process was used to develop a novel density prediction approach that can be adapted for any given powder feedstock and LPBF system. First, calibration coupons were built using IN625, Ti64 and Fe powders and a specific LPBF system. These coupons were manufactured using the predetermined ranges of laser power, scanning speed, hatching space, and layer thickness, and their densities were measured using conventional material characterization techniques. Next, a simplified melt pool model was used to calculate the melt pool dimensions for the selected sets of printing parameters. Both sets of data were then combined to predict the density of printed parts. This approach was additionally validated using the literature data on AlSi10Mg and 316L alloys, thus demonstrating that it can reliably be used to optimize the laser powder bed metal fusion process.
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ISSN:2504-4494
2504-4494
DOI:10.3390/jmmp3010021