• Advances in aircraft and spacecraft science
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• v.8 no.1
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• pp.31-51
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• 2021

Selective laser melting (SLM), one of the most widely used powder bed fusion (PBF) additive manufacturing (AM) technology, enables the fabrication of customized metallic parts with complex geometry by layer-by-layer fashion. However, SLM inherently poses several problems such as the discontinuities in the molten track and the steep temperature gradient resulting in a high degree of residual stress. To avoid such defects, thisstudy proposes a temperature thread multiscale model of SLM for the evaluation of the process at different scales. In microscale melt pool analysis, the laser beam parameters were evaluated based on the predicted melt pool morphology to check for lack-of-fusion or keyhole defects. The analysis results at microscale were then used to build an equivalent body heat flux model to obtain the residual stress distribution and the part distortions at the macroscale (part level). To identify the source of uneven heat dissipation, a liquid lifetime contour at macroscale was investigated. The predicted distortion was also experimentally validated showing a good agreement with the experimental measurement.

• Journal of the Korea Academia-Industrial cooperation Society
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• v.19 no.12
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• pp.25-31
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• 2018

Selective Laser Melting is one of the representative 3D printing techniques for handling metal materials. The main factors influencing the characteristics of structures fabricated by the SLM method include the build-up angle of structures, laser power, laser scan speed, and scan spacing. In this study, the tensile properties of AlSi10Mg alloys were investigated by considering the build-up angle of tensile test specimens, laser scanning speed and scan spacing as variables. The yield stress, tensile strength, and elongation were considered as tensile properties. From the test results, it was confirmed that the yield stress values were lowered in the order of 0, 45, and 90 based on the manufacturing direction of the tensile specimen. The maximum yield stress value was obtained at 1870 mm / min based on the laser scan speed. The yield stress size decreased with decreasing scan speed. Based on the laser scan spacing, as the value increases, the yield stress increases, but the variation is smaller than the other test criteria. The tendency of the tensile strength and elongation variation depending on the test conditions was difficult to understand.

• The Journal of Korean Academy of Prosthodontics
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• v.59 no.2
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• pp.248-260
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• 2021

Cobalt-chromium alloys are used to fabricate various dental prostheses, and have advantages of low cost and excellent mechanical properties compared to other alloys. Recently, selective laser melting, which is an additive manufacturing method, has been used to overcome the disadvantages of the conventional fabrication method. A local rapid heating and cooling process of selective laser melting induces fine microstructures, grain refinement, and reduction of porosities of the alloys. Therefore, it can improve mechanical properties compared to the alloys fabricated by the conventional method. On the other hand, layering process and rapid heating and cooling cause accumulation of a large amount of residual stresses that can adversely affect the mechanical properties. A heat treatment for removing residual stresses through recovery and recrystallization process caused complicated changes in mechanical properties induced by phase transformation, precipitate and homogenization of the microstructures. The purpose of this review was to compare the manufacturing methods of Co-Cr alloys and to investigate the characteristics of Co-Cr alloys fabricated by selective laser melting.

• Journal of the Korean Society of Manufacturing Process Engineers
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• v.21 no.7
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• pp.10-20
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• 2022

Recently, metal additive manufacturing (AM) is being investigated as a new manufacturing technology. In metal AM, powder bed fusion (PBF) is a promising technology that can be used to manufacture small and complex metallic components by selectively fusing each powder layer using an energy source such as laser or an electron beam. PBF includes selective laser melting (SLM) and electron beam melting (EBM). SLM uses high power-density laser to melt and fuse metal powders. EBM is similar to SLM but melts metals using an electron beam. When these processes are applied, the mechanical properties and microstructures change due to the many parameters involved. Therefore, this study is conducted to investigate the effects of the parameters on the mechanical properties and microstructures such that the processes can be performed more economically and efficiently.

• Journal of the Korean Crystal Growth and Crystal Technology
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• v.28 no.5
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• pp.217-221
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• 2018

Selective laser melting (SLM) technique is one of the additive manufacturing processes, in which functional, complex parts can be directly manufactured by selective melting layers of powder. SLM technique has received great attention due to offering a facile part-manufacturing route and utilizing a hard-to-manufacturing material (e.g. Ti6Al4V). The SLM process allows the accurate fabrication of near-net shaped parts and the significant reduction in the consumption of raw materials when compared to the traditional manufacturing processes such as casting and/or forging. In this study, we focus the high-speed additive manufacturing of Ti6Al4V parts in the aspect of manufacturing time, controlling various process parameters.

• Archives of Metallurgy and Materials
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• v.64 no.2
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• pp.571-578
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• 2019

The densification behavior of H13 tool steel powder by dual speed laser scanning strategy have been characterized for selective laser melting process, one of powder bed fusion based metal 3d printing. Under limited given laser power, the laser re-melting increases the relative density and hardness of H13 tool steel with closing pores. The single melt-pool analysis shows that the pores are located on top area of melt pool when the scanning speed is over 400 mm/s while the low scanning speed of 200 mm/s generates pores beneath the melt pool in the form of keyhole mode with the high energy input from the laser. With the second laser scanning, the pores on top area of melt pools are efficiently closed with proper dual combination of scan speed. However pores located beneath the melt pools could not be removed by second laser scanning. When each layer of 3d printing are re-melted, the relative density and hardness are improved for most dual combination of scanning. Among the scan speed combination, the 600 mm/s by 400 mm/s leads to the highest relative density, 99.94 % with hardness of 53.5 HRC. This densification characterization with H13 tool steel laser re-melting can be efficiently applied for tool steel component manufacturing via metal 3d printing.

• Transactions of Materials Processing
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• v.18 no.3
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• pp.262-267
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• 2009

Selective laser sintering is a kind of rapid prototyping process whereby a three-dimensional part is built layer wise by laser scanning the powder. This process is highly influenced by powder and laser parameters such as laser power, scan rate, fill spacing and layer thickness. Therefore a study on fabricating Fe-Ni-Cr powder by selective laser sintering has been performed. In this study, fabrication was performed by experimental facilities consisting of a 200W fiber laser which can be focused to 0.08mm and atmospheric chamber which can control atmospheric pressure with argon. With power increase or energy density decrease, line width was decreased and line surface quality was improved with energy density increase. Surface quality of quadrangle structure was improved with fill spacing optimization.

• Journal of Powder Materials
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• v.26 no.6
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• pp.471-476
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• 2019

Additively manufactured metallic components contain high surface roughness values, which lead to unsatisfactory high cycle fatigue resistance. In this study, high cycle fatigue properties of selective laser melted Ti-6Al-4V alloy are investigated and the effect of dry-electropolishing, which does not cause weight loss, on the fatigue resistance is also examined. To reduce the internal defect in the as-built Ti-6Al-4V, first, hot isostatic pressing (HIP) is conducted. Then, to improve the mechanical properties, solution treatment and aging are also implemented. Selective laser melting (SLM)-built Ti64 shows a primary α and secondary α+β lamellar structure. The sizes of secondary α and β are approximately 2 ㎛ and 100 nm, respectively. On the other hand, surface roughness Ra values of before and after dry-electropolishing are 6.21 ㎛ and 3.15 ㎛, respectively. This means that dry-electropolishing is effective in decreasing the surface roughness of selective laser melted Ti-6Al-4V alloy. The comparison of high cycle fatigue properties between before and after dry-electropolished samples shows that reduced surface roughness improves the fatigue limit from 150 MPa to 170 MPa. Correlations between surface roughness and high cycle fatigue properties are also discussed based on these findings.

• Journal of Powder Materials
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• v.25 no.6
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• pp.475-481
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• 2018

Selective laser melting (SLM), a type of additive manufacturing (AM) technology, leads a global manufacturing trend by enabling the design of geometrically complex products with topology optimization for optimized performance. Using this method, three-dimensional (3D) computer-aided design (CAD) data components can be built up directly in a layer-by-layer fashion using a high-energy laser beam for the selective melting and rapid solidification of thin layers of metallic powders. Although there are considerable expectations that this novel process will overcome many traditional manufacturing process limits, some issues still exist in applying the SLM process to diverse metallic materials, particularly regarding the formation of porosity. This is a major processing-induced phenomenon, and frequently observed in almost all SLM-processed metallic components. In this study, we investigate the mechanical anisotropy of SLM-produced 316L stainless steel based on microstructural factors and highly-oriented porosity. Tensile tests are performed to investigate the microstructure and porosity effects on mechanical anisotropy in terms of both strength and ductility.

• Journal of Powder Materials
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• v.30 no.5
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• pp.431-435
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• 2023

An irradiation hardening of Inconel 718 produced by selective laser melting (SLM) was studied based on the microstructural observation and mechanical behavior. Ion irradiation for emulating neutron irradiation has been proposed owing to advantages such as low radiation emission and short experimental periods. To prevent softening caused by the dissolution of γ' and γ" precipitates due to irradiation, only solution annealing (SA) was performed. SLM SA Inconel 718 specimen was ion irradiated to demonstrate the difference in microstructure and mechanical properties between the irradiated and non-irradiated specimens. After exposing specimens to Fe³⁺ ions irradiation up to 100 dpa (displacement per atom) at an ambient temperature, the hardness of irradiated specimens was measured by nano-indentation as a function of depth. The depth distribution profile of Fe³⁺ and dpa were calculated by the Monte Carlo SRIM (Stopping and Range of Ions in Matter)-2013 code under the assumption of the displacement threshold energy of 40 eV. A transmission electron microscope was utilized to observe the formation of irradiation defects such as dislocation loops. This study reveals that the Frank partial dislocation loops induce irradiation hardening of SLM SA Inconel 718 specimens.