A4 Refereed article in a conference publication

Validation of powder layering simulation via packing density measurement for laser-based powder bed fusion




AuthorsHaapa Erik, Gopaluni Aditya, Piili Heidi, Ganvir Ashish, Salminen Antti, Ottelin Juha

EditorsAntti Salminen, Ashish Ganvir, Heidi Piili, Mohsen Amraei, Andrey Mityakov

Conference nameNordic Laser Materials Processing Conference

Publication year2023

JournalIOP Conference Series: Materials Science and Engineering

Book title NOLAMP- Nordic Laser Materials Processing Conference (19TH-NOLAMP-2023) 22/08/2023 - 24/08/2023 Turku, Finland

Series titleIOP Conference Series: Materials Science and Engineering

Volume1296

First page 012020

ISSN1757-8981

eISSN1757-899X

DOIhttps://doi.org/10.1088/1757-899X/1296/1/012020

Web address https://iopscience.iop.org/article/10.1088/1757-899X/1296/1/012020

Self-archived copy’s web addresshttps://research.utu.fi/converis/portal/detail/Publication/182416735


Abstract

Powder bed fusion using a laser beam (PBF-LB/M) is considered one of the most versatile additive manufacturing methods as the parts printed have high resolution thanks to the low layer thickness used. The powder packing density (PD) of the powder layer has a significant impact on the density, surface roughness and other mechanical properties of the built parts. Due to the difficulty of characterizing the powder bed in situ, simulation has often been used to study the powder behavior on the powder bed. However, in order for the simulation to have practical value, there must be some way of confirming the results via experimental methods, also called validation. The aim of this study was to develop a powder packing density-based validation method for a powder bed simulation. The developed method featured a simplistic "open cup" style sample which traps powder inside for PD measurement. The samples were built with an EOS M 290 PBF-LB/M system using Alloy 718 (also known as "IN718" or "Inconel") powder. Average PD over the five built samples was 52.4 %, with a standard deviation of 0.2 %. The method was used to successfully validate a powder bed simulation with four recoated powder layers, modelled using FLOW-3D DEM simulation software from Flow Science Inc. Similar methods for PD characterization were found in literature, but in many cases the method does not fully correspond to the conditions of a simulated powder bed, the scale is very small, or the reliability of the PD measurement is not confirmed. The method presented in this study corresponds to typical powder bed simulation conditions, while retaining high reliability and repeatability of results.


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