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Pandora’s Box–Influence of Contour Parameters on Roughness and Subsurface Residual Stresses in Laser Powder Bed Fusion of Ti-6Al-4V

  • The contour scan strategies in laser powder bed fusion (LPBF) of Ti-6Al-4V were studied at the coupon level. These scan strategies determined the surface qualities and subsurface residual stresses. The correlations to these properties were identified for an optimization of the LPBF processing. The surface roughness and the residual stresses in build direction were linked: combining high laser power and high scan velocities with at least two contour lines substantially reduced the surface roughness, expressed by the arithmetic mean height, from values as high as 30 μm to 13 μm, while the residual stresses rose from ~340 to about 800 MPa. At this stress level, manufactured rocket fuel injector components evidenced macroscopic cracking. A scan strategy completing the contour region at 100 W and 1050 mm/s is recommended as a compromise between residual stresses (625 MPa) and surface quality (14.2 μm). The LPBF builds were monitored with an in-line twin-photodiode-based melt pool monitoringThe contour scan strategies in laser powder bed fusion (LPBF) of Ti-6Al-4V were studied at the coupon level. These scan strategies determined the surface qualities and subsurface residual stresses. The correlations to these properties were identified for an optimization of the LPBF processing. The surface roughness and the residual stresses in build direction were linked: combining high laser power and high scan velocities with at least two contour lines substantially reduced the surface roughness, expressed by the arithmetic mean height, from values as high as 30 μm to 13 μm, while the residual stresses rose from ~340 to about 800 MPa. At this stress level, manufactured rocket fuel injector components evidenced macroscopic cracking. A scan strategy completing the contour region at 100 W and 1050 mm/s is recommended as a compromise between residual stresses (625 MPa) and surface quality (14.2 μm). The LPBF builds were monitored with an in-line twin-photodiode-based melt pool monitoring (MPM) system, which revealed a correlation between the intensity quotient I2/I1, the surface roughness, and the residual stresses. Thus, this MPM system can provide a predictive estimate of the surface quality of the samples and resulting residual stresses in the material generated during LPBF.zeige mehrzeige weniger

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Metadaten
Autoren/innen:K. Artzt, Tatiana Mishurova, P.-P. Bauer, J. Gussone, P. Barriobero-Vila, Sergei Evsevleev, Giovanni Bruno, G. Requena, J. Haubrich
Dokumenttyp:Zeitschriftenartikel
Veröffentlichungsform:Verlagsliteratur
Sprache:Englisch
Titel des übergeordneten Werkes (Englisch):Materials
Jahr der Erstveröffentlichung:2020
Organisationseinheit der BAM:8 Zerstörungsfreie Prüfung
8 Zerstörungsfreie Prüfung / 8.5 Mikro-ZfP
Veröffentlichende Institution:Bundesanstalt für Materialforschung und -prüfung (BAM)
Jahrgang/Band:13
Ausgabe/Heft:15
Erste Seite:3348
DDC-Klassifikation:Technik, Medizin, angewandte Wissenschaften / Ingenieurwissenschaften / Ingenieurwissenschaften und zugeordnete Tätigkeiten
Freie Schlagwörter:Additive manufacturing; Contour scan strategy; Melt pool monitoring; Residual stress; Surface roughness; Synchrotron X-ray diffraction; Ti-6Al-4V
Themenfelder/Aktivitätsfelder der BAM:Material
Material / Materialien und Stoffe
DOI:https://doi.org/10.3390/ma13153348
URN:urn:nbn:de:kobv:b43-510585
Verfügbarkeit des Dokuments:Datei für die Öffentlichkeit verfügbar ("Open Access")
Lizenz (Deutsch):License LogoCreative Commons - CC BY - Namensnennung 4.0 International
Datum der Freischaltung:29.07.2020
Referierte Publikation:Ja
Datum der Eintragung als referierte Publikation:10.08.2020
Schriftenreihen ohne Nummerierung:Wissenschaftliche Artikel der BAM