Browsing by Subject "Laser Beam Melting"
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Item Error Detection in Laser Beam Melting Systems by High Resolution Imaging(University of Texas at Austin, 2012-08-15) Kleszczynski, S.; zur Jacobsmühlen, J.; Sehrt, J.T.; Witt, G.Laser Beam Melting as a member of Additive Manufacturing processes allows the fabrication of three-dimensional metallic parts with almost unlimited geometrical complexity and very good mechanical properties. However, its potential in areas of application such as aerospace or medicine has not yet been exploited due to the lack of process stability and quality management. For that reason samples with pre-defined process irregularities are built and the resulting errors are detected using high-resolution imaging. This paper presents an overview of typical process errors and proposes a catalog of measures to reduce process breakdowns. Based on this systematical summary a future contribution to quality assurance and process documentation is aspired.Item Position Dependency of Surface Roughness in Parts from Laser Beam Melting Systems(University of Texas at Austin, 2015) Kleszczynski, S.; Ladewig, A.; Friedberger, K.; zur Jacobsmühlen, J.; Merhof, D.; Witt, G.Laser Beam Melting is a promising Additive Manufacturing technology for the production of complex metal components. During batch production of multiple identical parts in a single build job, we observed parts with deviating surface roughness in certain areas, which all faced away from the laser. This suggests a dependency of surface roughness on the part position in the build chamber. In this work we systematically reproduce and analyze this effect. We place hollow pyramids with twelve faces and two different overhanging angles at nine positions on the substrate plate and build this setup twice, using an imaging setup for process documentation. Surface roughness is measured by contact profilometry on three lines for each pyramid face. Our experiments reproduce the effect. Based on these findings we present a hypothesis for the cause and show metallographic images to support our theory. As a consequence, the position relative to the laser should be considered in the design phase for parts with high surface quality requirements.Item Processability of high strength Aluminum-Copper alloys AW-2022 and 2024 by Laser Beam Melting in Powder Bed(University of Texas at Austin, 2014) Karg, M.; Ahuja, B.; Kuryntsev, S.; Gorunov, A.; Schmidt, M.Additive Manufacturing offers geometric freedom excellently suited for topology optimized light weight designs. Ideally these should be produced from materials of high strength to weight ratio such as aluminium-copper alloys. Yet these are considered unsuitable for welding. With Laser Beam Melting of Metals in powder bed (LBM), the only class of aluminium alloys widely processed is that of aluminium-silicon alloys, which are easily weldable and castable, too. In this contribution we present results of LBM high-strength aluminium-copper alloys AW-2022 and AW-2024 under variation of laser power, scan speed and hatch distance. We achieved relative densities well above 99 %. We analyzed thin walls, compared process windows as well as microstructures observed using etched metallographic microsections. We analyzed the chemical constitution of powders and produced samples using ICP-OES.Item Thermal Treatments of AlSi10Mg Processed by Laser Beam Melting(University of Texas at Austin, 2015) Mertens, A.; Dedry, O.; Reuter, D.; Rigo, O.; Lecomte-Beckers, J.Recent studies have shown that AlSi10Mg processed by Laser Beam Melting (LBM) exhibits a much finer microstructure when compared to its cast counterpart as a consequence of the much faster cooling rates imposed in the LBM process. Such microstructural refinement causes a significant increase in strength and hardness, to such an extent that as-fabricated LBM AlSi10Mg was reported to present hardness value of 127 ± 3 Hv0.5, similar to the hardness of high pressure die cast AlSi10Mg in the aged condition (i.e. 130-133 Hv). Yet, little attention has been given so far to the influence of thermal treatments on the microstructure and mechanical behavior of LBM AlSi10Mg. The present work hence aims to investigate the effect of two different types of heat treatments – i.e. (i) stress relief and (ii) solutionizing and ageing − on the microstructure, hardness and tensile properties of LBM AlSi10Mg.