Experimental and Computational Study of Area Printing™ Additive Manufacturing: Inconel 718 and M300 Maraging Steel Density Improvement

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Fotovvati, B.
Shrestha, S.
Ferreri, N.
Duanmu, N.

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University of Texas at Austin


The low manufacturing speed of laser-powder bed fusion (LPBF) additive manufacturing has hindered its adoption in conventional manufacturing methods. Large-area pulsed laser powder bed fusion (LAPBF), also known as "Area Printing™", has addressed this limitation by replacing the point laser with a large-area pulsed laser. Each pulse melts a region of the powder bed in the order of square millimeters, which enables scalability without the sacrifice of resolution and high throughput at an equivalent or better quality (in part due to a lack of spatter) when compared to conventional LPBF methods. In this study, process parameters are optimized to achieve near-fulldensity parts, and a computational model is developed to understand the multi-physics governing the process. It is observed that the shallow depth and high aspect ratio of the melt pool lead to a unidirectional solidification front extending along the build direction where grains grow epitaxially, and highly directional microstructures are created.


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