On the use of multiple layer thicknesses within laser powder bed fusion and the effect on mechanical properties

Laser Powder Bed fusion is capable of rapid production of parts, from conception, compared with traditional manufacturing methods. This said, the time taken to fabricate a single part can still be significant – typically many hours. Processing thicker layers, and hence fewer total layers, in the Las...

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Autores principales:	Alex Gullane, James W. Murray, Christopher J. Hyde, Simon Sankare, Alper Evirgen, Adam T. Clare
Formato:	article
Lenguaje:	EN
Publicado:	Elsevier 2021
Materias:	Additive Manufacturing Laser Powder Bed Fusion Layer thickness Tensile properties Production rate Local properties Materials of engineering and construction. Mechanics of materials TA401-492
Acceso en línea:	https://doaj.org/article/575ef84face9429fb975b7bac56106c5
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spelling	oai:doaj.org-article:575ef84face9429fb975b7bac56106c52021-11-20T04:55:46ZOn the use of multiple layer thicknesses within laser powder bed fusion and the effect on mechanical properties0264-127510.1016/j.matdes.2021.110256https://doaj.org/article/575ef84face9429fb975b7bac56106c52021-12-01T00:00:00Zhttp://www.sciencedirect.com/science/article/pii/S026412752100811Xhttps://doaj.org/toc/0264-1275Laser Powder Bed fusion is capable of rapid production of parts, from conception, compared with traditional manufacturing methods. This said, the time taken to fabricate a single part can still be significant – typically many hours. Processing thicker layers, and hence fewer total layers, in the Laser Powder Bed Fusion process, is an effective way to reduce build times. However, mechanical performance can suffer as a result of this strategy. This study proposes and demonstrates a method to enable the interlacing of multiple layer thicknesses within one part, allowing for finer layers within regions where they are specifically required, whilst maintaining overall component integrity for specific load cases. Thicker layers are used within regions with lower property requirements in order to optimise an overall part for improved production rate. The design of interfaces between two disparate layer thickness regions could also be tailored for control of material properties and such will be investigated in an independent study. Ti6Al4V LPBF samples are fabricated, characterised by way of tensile testing, porosity analysis and microstructural analysis. The study demonstrate parts can be additively built using multiple layer thickness regions with consistent ultimate tensile strength (1110–1135 MPa) and varying penalties to ductility, depending on layer thickness and interface design (elongation to failure reductions up to 40% in the most extreme case).Alex GullaneJames W. MurrayChristopher J. HydeSimon SankareAlper EvirgenAdam T. ClareElsevierarticleAdditive ManufacturingLaser Powder Bed FusionLayer thicknessTensile propertiesProduction rateLocal propertiesMaterials of engineering and construction. Mechanics of materialsTA401-492ENMaterials & Design, Vol 212, Iss , Pp 110256- (2021)
institution	DOAJ
collection	DOAJ
language	EN
topic	Additive Manufacturing Laser Powder Bed Fusion Layer thickness Tensile properties Production rate Local properties Materials of engineering and construction. Mechanics of materials TA401-492
spellingShingle	Additive Manufacturing Laser Powder Bed Fusion Layer thickness Tensile properties Production rate Local properties Materials of engineering and construction. Mechanics of materials TA401-492 Alex Gullane James W. Murray Christopher J. Hyde Simon Sankare Alper Evirgen Adam T. Clare On the use of multiple layer thicknesses within laser powder bed fusion and the effect on mechanical properties
description	Laser Powder Bed fusion is capable of rapid production of parts, from conception, compared with traditional manufacturing methods. This said, the time taken to fabricate a single part can still be significant – typically many hours. Processing thicker layers, and hence fewer total layers, in the Laser Powder Bed Fusion process, is an effective way to reduce build times. However, mechanical performance can suffer as a result of this strategy. This study proposes and demonstrates a method to enable the interlacing of multiple layer thicknesses within one part, allowing for finer layers within regions where they are specifically required, whilst maintaining overall component integrity for specific load cases. Thicker layers are used within regions with lower property requirements in order to optimise an overall part for improved production rate. The design of interfaces between two disparate layer thickness regions could also be tailored for control of material properties and such will be investigated in an independent study. Ti6Al4V LPBF samples are fabricated, characterised by way of tensile testing, porosity analysis and microstructural analysis. The study demonstrate parts can be additively built using multiple layer thickness regions with consistent ultimate tensile strength (1110–1135 MPa) and varying penalties to ductility, depending on layer thickness and interface design (elongation to failure reductions up to 40% in the most extreme case).
format	article
author	Alex Gullane James W. Murray Christopher J. Hyde Simon Sankare Alper Evirgen Adam T. Clare
author_facet	Alex Gullane James W. Murray Christopher J. Hyde Simon Sankare Alper Evirgen Adam T. Clare
author_sort	Alex Gullane
title	On the use of multiple layer thicknesses within laser powder bed fusion and the effect on mechanical properties
title_short	On the use of multiple layer thicknesses within laser powder bed fusion and the effect on mechanical properties
title_full	On the use of multiple layer thicknesses within laser powder bed fusion and the effect on mechanical properties
title_fullStr	On the use of multiple layer thicknesses within laser powder bed fusion and the effect on mechanical properties
title_full_unstemmed	On the use of multiple layer thicknesses within laser powder bed fusion and the effect on mechanical properties
title_sort	on the use of multiple layer thicknesses within laser powder bed fusion and the effect on mechanical properties
publisher	Elsevier
publishDate	2021
url	https://doaj.org/article/575ef84face9429fb975b7bac56106c5
work_keys_str_mv	AT alexgullane ontheuseofmultiplelayerthicknesseswithinlaserpowderbedfusionandtheeffectonmechanicalproperties AT jameswmurray ontheuseofmultiplelayerthicknesseswithinlaserpowderbedfusionandtheeffectonmechanicalproperties AT christopherjhyde ontheuseofmultiplelayerthicknesseswithinlaserpowderbedfusionandtheeffectonmechanicalproperties AT simonsankare ontheuseofmultiplelayerthicknesseswithinlaserpowderbedfusionandtheeffectonmechanicalproperties AT alperevirgen ontheuseofmultiplelayerthicknesseswithinlaserpowderbedfusionandtheeffectonmechanicalproperties AT adamtclare ontheuseofmultiplelayerthicknesseswithinlaserpowderbedfusionandtheeffectonmechanicalproperties
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On the use of multiple layer thicknesses within laser powder bed fusion and the effect on mechanical properties

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