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Article
Publication date: 17 September 2021

Sareh Götelid, Taoran Ma, Christophe Lyphout, Jesper Vang, Emil Stålnacke, Jonas Holmberg, Seyed Hosseini and Annika Strondl

This study aims to investigate additive manufacturing of nickel-based superalloy IN718 made by powder bed fusion processes: powder bed fusion laser beam (PBF-LB) and powder

Abstract

Purpose

This study aims to investigate additive manufacturing of nickel-based superalloy IN718 made by powder bed fusion processes: powder bed fusion laser beam (PBF-LB) and powder bed fusion electron beam (PBF-EB).

Design/methodology/approach

This work has focused on the influence of building methods and post-fabrication processes on the final part properties, including microstructure, surface quality, residual stresses and mechanical properties.

Findings

PBF-LB produced a much smoother surface. Blasting and shot peening (SP) reduced the roughness even more but did not affect the PBF-EB surface finish as much. As-printed PBF-EB parts have low residual stresses in all directions, whereas it was much higher for PBF-LB. However, heat treatment removed the stresses and SP created compressive stresses for samples from both PBF processes. The standard Arcam process parameter for PBF-EB for IN718 is not fully optimized, which leads to porosity and inferior mechanical properties. However, impact toughness after hot isostatic pressing was surprisingly high.

Originality/value

The two processes gave different results and also responses to post-treatments, which could be of advantage or disadvantage for different applications. Suggestions for improving the properties of parts produced by each method are presented.

Open Access
Article
Publication date: 4 August 2021

Francesco Sillani, Dominik Wagner, Marvin Aaron Spurek, Lukas Haferkamp, Adriaan Bernardus Spierings, Manfred Schmid and Konrad Wegener

Powder bed-based additive manufacturing (AM) is a promising family of technologies for industrial applications. The purpose of this study is to provide a new metrics based…

Abstract

Purpose

Powder bed-based additive manufacturing (AM) is a promising family of technologies for industrial applications. The purpose of this study is to provide a new metrics based on the analysis of the compaction behavior for the evaluation of flowability of AM powders.

Design/methodology/approach

In this work, a novel qualification methodology based on a camera mounted onto a commercially available tap density meter allowed to assess the compaction behavior of a selection of AM materials, both polymers and metals. This methodology automatizes the reading of the powder height and obtains more information compared to ASTM B527. A novel property is introduced, the “tapping modulus,” which describes the packing speed of a powdered material and is related to a compression/vibration powder flow.

Findings

The compaction behavior was successfully correlated with the dynamic angle of repose for polymers, but interestingly not for metals, shedding more light to the different flow behavior of these materials.

Research limitations/implications

Because of the chosen materials, the results may lack generalizability. For example, the application of this methodology outside of AM would be interesting.

Originality/value

This paper suggests a new methodology for assessing the flowing behavior of AM materials when subjected to compression. The device is inexpensive and easy to implement in a quality assurance environment, being thus interesting for industrial applications.

Details

Rapid Prototyping Journal, vol. 27 no. 11
Type: Research Article
ISSN: 1355-2546

Keywords

Article
Publication date: 10 June 2021

Anna Liebrich, Horst-Christian Langowski, Regina Schreiber and Bernd R. Pinzer

This study aims to investigate the effect of the material thickness and build orientation on the mass transfer of low molecular weight substances through polyamide 12…

67

Abstract

Purpose

This study aims to investigate the effect of the material thickness and build orientation on the mass transfer of low molecular weight substances through polyamide 12 (PA12) structures produced by laser sintering (LS).

Design/methodology/approach

Disc-shaped PA12 sheets having a nominal thickness ranging from 700 to 2,000 µm were built in horizontal, vertical and diagonal orientations and their permeation properties to oxygen and water vapor were measured. The structural properties of the sheets were examined by X-ray micro-computed tomography, differential scanning calorimetry and polarized light microscopy.

Findings

All the LS sheets that were investigated had water vapor and oxygen permeation coefficients that are in the range of those of PA12 produced by traditional manufacturing technologies. Despite significant differences in the porosity characteristics, the permeation properties of sheets built in different orientations were similar. The pores seem to have no measurable effect on the mass transfer rates in the sheets, and the transport processes seem to predominantly follow the rules of a regular solution-diffusion mechanism. The results showed a non-significant trend toward thickness-dependent permeation coefficients, which agrees with the observed differences in the crystal structures of the sheets.

Practical implications

The results are an important basis for the qualification of LS technology for direct manufacturing in applications requiring special barrier performance.

Originality/value

This study provides new information on mechanisms of mass transport through LS PA12 and the effect of the material thickness and build orientation. Furthermore, the results enhance understanding of the structural properties of thin polymeric sheets produced by LS.

Details

Rapid Prototyping Journal, vol. 27 no. 5
Type: Research Article
ISSN: 1355-2546

Keywords

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