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Laser powder bed fusion of water-atomized iron-based powders: process optimization

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Letenneur, Morgan, Brailovski, Vladimir, Kreitcberg, Alena, Paserin, Vladimir et Bailon-Poujol, Ian. 2017. « Laser powder bed fusion of water-atomized iron-based powders: process optimization ». Journal of Manufacturing and Materials Processing, vol. 1, nº 2.

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Abstract

The laser powder bed fusion (L-PBF) technology was adapted for use with non-spherical low-cost water-atomized iron powders. A simplified numerical and experimental modeling approach was applied to determine—in a first approximation—the operation window for the selected powder in terms of laser power, scanning speed, hatching space, and layer thickness. The operation window, delimited by a build rate ranging from 4 to 25 cm3/h, and a volumetric energy density ranging from 50 to 190 J/mm3, was subsequently optimized to improve the density, the mechanical properties, and the surface roughness of the manufactured specimens. Standard L-PBF-built specimens were subjected to microstructural (porosity, grain size) and metrological (accuracy, shrinkage, minimum wall thickness, surface roughness) analyses and mechanical testing (three-point bending and tensile tests). The results of the microstructural, metrological and mechanical characterizations of the L-PBF-built specimens subjected to stress relieve annealing and hot isostatic pressing were then compared with those obtained with conventional pressing-sintering technology. Finally, by using an energy density of 70 J/mm3 and a build rate of 9 cm3/h, it was possible to manufacture 99.8%-dense specimens with an ultimate strength of 330 MPa and an elongation to failure of 30%, despite the relatively poor circularity of the powder used.

Item Type: Peer reviewed article published in a journal
Additional Information: Identifiant de l'article: 23
Professor:
Professor
Brailovski, Vladimir
Affiliation: Génie mécanique
Date Deposited: 18 Dec 2017 17:24
Last Modified: 27 Jun 2018 18:13
URI: http://espace2.etsmtl.ca/id/eprint/16031

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