Process Parameter Optimization for Laser Powder Bed Fusion of Fe-Si Alloy Considering Surface Morphology and Track Width of Single Scan Track

• Published in: Materials Vol. 16; no. 24; p. 7626
• Main Authors: Jang, Ho Sung, Kim, Su Heon, Park, Geon-Woo, Jeon, Jong Bae, Kim, Donghwi, Kim, Dohyung, Kim, Wang Ryeol, Choi, Yoon Suk, Shin, Sunmi
• Format: Journal Article
• Language: English
• Published: Switzerland MDPI AG 13.12.2023
• Subjects: Additive manufacturing; Beds (process engineering); Ferrous alloys; Lasers; Manufacturing; Morphology; Optimization; Powder beds; process optimization; Process parameters; selective laser melting; silicon steel; single-track scanning; Japan; process optimization; selective laser melting; additive manufacturing; silicon steel; single-track scanning
• ISSN: 1996-1944; 1996-1944
• DOI: 10.3390/ma16247626

A laser power bed fusion (L-PBF) manufacturing process was optimized by analyzing the surface morphology and track width of single scan tracks (SSTs) on Fe-3.4wt.%Si. An SST was evaluated under process conditions of laser power , scan speed , and energy density = / . The SST surface shape was mainly affected by ; desirable thin and regular tracks were obtained at = 0.3 and 0.4 J/mm. An L-PBF process window was proposed considering the optimal of SST, and the appropriate range of for the alloy was identified to be 0.24 J/mm to 0.49 J/mm. showed a strong relationship with and , and an analytic model was suggested. To verify the process window derived from the appropriate of SST, cubic samples were manufactured with the estimated optimal process conditions. Most samples produced had a high density with a porosity of <1%, and the process window derived from SST data had high reliability. This study presents a comprehensive approach to enhancing additive manufacturing for Fe-3.4Si alloy, offering valuable insights for achieving high-quality samples without the need for time-intensive procedures.