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Influences of powder morphology and spreading parameters on the powder bed topography uniformity in powder bed fusion metal additive manufacturing

Mussatto, Andre orcid logoORCID: 0000-0001-5335-7968, Robert, Groarke, O'Neill, Aidan, Ahmed Obeidi, Muhannad orcid logoORCID: 0000-0003-2733-3828, Delauré, Yan orcid logoORCID: 0000-0002-7151-9278 and Brabazon, Dermot orcid logoORCID: 0000-0003-3214-6381 (2020) Influences of powder morphology and spreading parameters on the powder bed topography uniformity in powder bed fusion metal additive manufacturing. Additive Manufacturing, 38 . ISSN 2214-7810

Abstract
Powder spreading is a crucial step in the powder bed fusion process, which controls the quality of powder bed and consequently affects the quality of printed parts. To date, however, powder spreadability has received very little attention and substantial fundamental work is still needed, largely because of the lack of experimental studies. Therefore, the focus of the present study addresses the influences of powder morphology, spreading velocity and layer thickness on the powder bed topography uniformity. The experiments were conducted with a laser powder bed fusion printer and the powder layers were spread systematically and comprehensively assessed. In summary, it was found that particle sphericity and surface texture dictates the degree of impact that the spreader velocity and the layer thickness exert on the quality of powder bed topography in spread layers. The spreader velocity has substantial influence on powder bed uniformity, such that better uniformity is achieved with low spreading velocities, ≤ 80 mm/s. Powders with a wide particle distribution and containing large number of fine particles (< 25 μm) enabled formation of uniform and dense powder beds, however such powders were found to be more affected by segregation. In addition to these observed effects, for the first time, the major process related challenges to powder spreadability and powder bed quality are reported in this study.
Metadata
Item Type:Article (Published)
Refereed:Yes
Additional Information:Article number: 101807
Uncontrolled Keywords:Powder spreadability; Powder rheology; Particle segregation; Selective laser melting; Stainless steel
Subjects:Engineering > Materials
Engineering > Mechanical engineering
Engineering > Production engineering
DCU Faculties and Centres:DCU Faculties and Schools > Faculty of Engineering and Computing > School of Mechanical and Manufacturing Engineering
Research Initiatives and Centres > Advanced Processing Technology Research Centre (APTRC)
Research Initiatives and Centres > I-Form
Publisher:Elsevier
Official URL:https://doi.org/10.1016/j.addma.2020.101807
Copyright Information:© 2020 The Authors. Open Access (CC-BY-4.0)
Funders:Science Foundation Ireland (SFI) under Grant Number 16/RC/3872, European Regional Development Fund.
ID Code:26094
Deposited On:09 Aug 2021 16:22 by Dermot Brabazon . Last Modified 27 May 2022 13:12
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