Browsing by Subject "direct metal laser melting"

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    A Direct Metal Laser Melting System Using a Continuously Rotating Powder Bed
    (University of Texas at Austin, 2019) Carter, William T.; Graham, Michael E.; Hayden, Christopher; Jeong, Younkoo; Mamrak, Justin; McCarthy, Brian; Monaghan, William; Nieters, Edward J.; Ostroverkhov, Victor; Roychowdhhury, Subhrajit; Schmitz, Andrea; Tucker, Michael R.
    The aircraft engine industry manufactures many metal parts of large diameter, but small cross-sectional area. Designers of these parts require increasingly complex geometries for improved aerodynamic efficiency and cooling. The combination of large diameter and complex geometric features inspired the development of a new Direct Metal Laser Melting (DMLM) architecture with a rotating powder bed. The system coordinates the rotational motion of a powder bed with an ascending laser scanner and recoater to build in a helical fashion. A single-point powder feeder delivers metal powder near the inner radius of an annular build volume, and the recoater spreads the powder to the outer radius in a “snow plow” fashion. Because the recoater and laser scanner are installed at different angular positions, they operate independently and simultaneously. A prototype system was built to demonstrate this concept for an aircraft engine combustor liner (600-mm dia. x 150-mm ht.) and showed continuous laser utilization exceeding 97%.
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    Optimization of Process Parameters for Reentrant Surfaces in Direct Metal Laser Melting
    (University of Texas at Austin, 2014) Ashby, Kathryn; Fieldman, Zack; Kenney, Pat; Rockstroh, Todd
    One of the key factors for development and optimization of direct metal laser melting (DMLM) is the analysis of process parameters on reentrant build geometry and surface finish. Recent studies have focused on the optimization of standard build parameters with only minor emphasis on reentrant geometries. Parameters that are not optimized often contribute to poor surface finish, difficult to remove supports, and failed-to-build geometries of reentrant surfaces that limit the capabilities of DMLM. Through the analysis of multiple studies with varying process parameters and input scan path geometry, open loop methods for creation and control of reentrant build geometries are assessed and presented.