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Contour design to improve topographical and microstructural characteristics of Alloy 718 manufactured by electron beam-powder bed fusion technique
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0001-6610-1486
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)
University West, Department of Engineering Science, Division of Subtractive and Additive Manufacturing. (PTW)ORCID iD: 0000-0002-7663-9631
University West, Department of Engineering Science, Division of Welding Technology. (PTW)ORCID iD: 0000-0001-9065-0741
2020 (English)In: Additive Manufacturing, ISSN 2214-8604, Vol. 32, article id 101014Article in journal (Refereed) Published
Abstract [en]

Additive manufacturing (AM) processes are being frequently used in industry as they allow the manufacture ofcomplex parts with reduced lead times. Electron beam-powder bed fusion (EB-PBF) as an AM technology isknown for its near-net-shape production capacity with low residual stress. However, the surface quality andgeometrical accuracy of the manufactured parts are major obstacles for the wider industrial adoption of thistechnology, especially when enhanced mechanical performance is taken into consideration. Identifying theorigins of surface features such as satellite particles and sharp valleys on the parts manufactured by EB-PBF isimportant for a better understanding of the process and its capability. Moreover, understanding the influence ofthe contour melting strategy, by altering process parameters, on the surface roughness of the parts and thenumber of near-surface defects is highly critical. In this study, processing parameters of the EB-PBF techniquesuch as scanning speed, beam current, focus offset, and number of contours (one or two) with the linear meltingstrategy were investigated. A sample manufactured using Arcam-recommended process parameters (threecontours with the spot melting strategy) was used as a reference. For the samples with one contour, the scanningspeed had the greatest effect on the arithmetical mean height (Sa), and for the samples with two contours, thebeam current and focus offset had the greatest effect. For the samples with two contours, a lower focus offset andlower scan speed (at a higher beam current) resulted in a lower Sa; however, increasing the scan speed for thesamples with one contour decreased Sa. In general, the samples with two contours provided a lower Sa (∼22 %)but with slightly higher porosity (∼8 %) compared to the samples with one contour. Fewer defects were detected with a lower scanning speed and higher beam current. The number of defects and the Sa value for thesamples with two contours manufactured using the linear melting strategy were ∼85 % and 16 %, respectively,lower than those of the reference samples manufactured using the spot melting strategy.

Place, publisher, year, edition, pages
2020. Vol. 32, article id 101014
Keywords [en]
3D printers; Additives; Electron beams; Scanning; Speed; Surface defects; Surface properties; Surface roughness, Alloy 718; Geometrical accuracy; Linear and spot melting strategies; Mechanical performance; Micro-structural characteristics; Near-surface defects; Powder bed; Processing parameters, Melting
National Category
Manufacturing, Surface and Joining Technology
Research subject
Production Technology; ENGINEERING, Manufacturing and materials engineering
Identifiers
URN: urn:nbn:se:hv:diva-14993DOI: 10.1016/j.addma.2019.101014Scopus ID: 2-s2.0-85078915522OAI: oai:DiVA.org:hv-14993DiVA, id: diva2:1395747
Available from: 2020-02-24 Created: 2020-02-24 Last updated: 2020-02-24Bibliographically approved

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Karimi Neghlani, PariaSadeghi, EsmaeilAndersson, Joel

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