Experimental investigations on the formation mechanisms of shrink lines in powder bed fusion of metals using a laser beam
The powder bed fusion of metals using a laser beam enables the tool-free fabrication of complex part geometries with merging areas and rapid cross-sectional changes. Together, these geometry features represent a structural transition leading to the formation of shrink lines. These notches on the sur...
Saved in:
| Main Authors: | , , , , |
|---|---|
| Format: | Article |
| Language: | English |
| Published: |
Elsevier
2024-11-01
|
| Series: | Advances in Industrial and Manufacturing Engineering |
| Subjects: | |
| Online Access: | http://www.sciencedirect.com/science/article/pii/S266691292400014X |
| Tags: |
Add Tag
No Tags, Be the first to tag this record!
|
| _version_ | 1846169370422673408 |
|---|---|
| author | Dominik Rauner David L. Wenzler Daniel Wolf Felix Granz Michael F. Zaeh |
| author_facet | Dominik Rauner David L. Wenzler Daniel Wolf Felix Granz Michael F. Zaeh |
| author_sort | Dominik Rauner |
| collection | DOAJ |
| description | The powder bed fusion of metals using a laser beam enables the tool-free fabrication of complex part geometries with merging areas and rapid cross-sectional changes. Together, these geometry features represent a structural transition leading to the formation of shrink lines. These notches on the surface of the part reduce the dimensional accuracy and the fatigue resistance. Shrink lines arise in various materials, with the dimensions of the shrink line depending on the geometric design. The formation mechanisms and influencing parameters of shrink lines have not been investigated yet. This paper demonstrates the extent of influence of the part geometry on the shrink line formation, which was quantified by varying the design of a representative structural transition. In addition, the positions of the specimens on the build platform and the scanning strategy were varied for deriving a cause-effect relationship using process monitoring. The results demonstrated that the shrink line formation was mainly caused by a local overheating at the structural transition and the global cooling behavior. The radius at the structural transition indicated the most significant impact among the investigated geometric parameters. The shrink line dimensions depended significantly on the orientation of the specimens on the build platform and the local scanning strategy applied at the height of the structural transition. The results can be used to reduce shrink lines by re-designing the part and to adjust the manufacturing strategy for structural transitions. |
| format | Article |
| id | doaj-art-d3f9b055e22e4184a956f8a91701192b |
| institution | Kabale University |
| issn | 2666-9129 |
| language | English |
| publishDate | 2024-11-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Advances in Industrial and Manufacturing Engineering |
| spelling | doaj-art-d3f9b055e22e4184a956f8a91701192b2024-11-13T04:30:30ZengElsevierAdvances in Industrial and Manufacturing Engineering2666-91292024-11-019100149Experimental investigations on the formation mechanisms of shrink lines in powder bed fusion of metals using a laser beamDominik Rauner0David L. Wenzler1Daniel Wolf2Felix Granz3Michael F. Zaeh4Corresponding author.; Technical University of Munich, Institute for Machine Tools and Industrial Management (iwb), Boltzmannstr. 15, 85748, Garching, GermanyTechnical University of Munich, Institute for Machine Tools and Industrial Management (iwb), Boltzmannstr. 15, 85748, Garching, GermanyTechnical University of Munich, Institute for Machine Tools and Industrial Management (iwb), Boltzmannstr. 15, 85748, Garching, GermanyTechnical University of Munich, Institute for Machine Tools and Industrial Management (iwb), Boltzmannstr. 15, 85748, Garching, GermanyTechnical University of Munich, Institute for Machine Tools and Industrial Management (iwb), Boltzmannstr. 15, 85748, Garching, GermanyThe powder bed fusion of metals using a laser beam enables the tool-free fabrication of complex part geometries with merging areas and rapid cross-sectional changes. Together, these geometry features represent a structural transition leading to the formation of shrink lines. These notches on the surface of the part reduce the dimensional accuracy and the fatigue resistance. Shrink lines arise in various materials, with the dimensions of the shrink line depending on the geometric design. The formation mechanisms and influencing parameters of shrink lines have not been investigated yet. This paper demonstrates the extent of influence of the part geometry on the shrink line formation, which was quantified by varying the design of a representative structural transition. In addition, the positions of the specimens on the build platform and the scanning strategy were varied for deriving a cause-effect relationship using process monitoring. The results demonstrated that the shrink line formation was mainly caused by a local overheating at the structural transition and the global cooling behavior. The radius at the structural transition indicated the most significant impact among the investigated geometric parameters. The shrink line dimensions depended significantly on the orientation of the specimens on the build platform and the local scanning strategy applied at the height of the structural transition. The results can be used to reduce shrink lines by re-designing the part and to adjust the manufacturing strategy for structural transitions.http://www.sciencedirect.com/science/article/pii/S266691292400014XMetal additive manufacturingLaser-based powder bed fusionStructural transitionMesoscale distortionOverheating |
| spellingShingle | Dominik Rauner David L. Wenzler Daniel Wolf Felix Granz Michael F. Zaeh Experimental investigations on the formation mechanisms of shrink lines in powder bed fusion of metals using a laser beam Advances in Industrial and Manufacturing Engineering Metal additive manufacturing Laser-based powder bed fusion Structural transition Mesoscale distortion Overheating |
| title | Experimental investigations on the formation mechanisms of shrink lines in powder bed fusion of metals using a laser beam |
| title_full | Experimental investigations on the formation mechanisms of shrink lines in powder bed fusion of metals using a laser beam |
| title_fullStr | Experimental investigations on the formation mechanisms of shrink lines in powder bed fusion of metals using a laser beam |
| title_full_unstemmed | Experimental investigations on the formation mechanisms of shrink lines in powder bed fusion of metals using a laser beam |
| title_short | Experimental investigations on the formation mechanisms of shrink lines in powder bed fusion of metals using a laser beam |
| title_sort | experimental investigations on the formation mechanisms of shrink lines in powder bed fusion of metals using a laser beam |
| topic | Metal additive manufacturing Laser-based powder bed fusion Structural transition Mesoscale distortion Overheating |
| url | http://www.sciencedirect.com/science/article/pii/S266691292400014X |
| work_keys_str_mv | AT dominikrauner experimentalinvestigationsontheformationmechanismsofshrinklinesinpowderbedfusionofmetalsusingalaserbeam AT davidlwenzler experimentalinvestigationsontheformationmechanismsofshrinklinesinpowderbedfusionofmetalsusingalaserbeam AT danielwolf experimentalinvestigationsontheformationmechanismsofshrinklinesinpowderbedfusionofmetalsusingalaserbeam AT felixgranz experimentalinvestigationsontheformationmechanismsofshrinklinesinpowderbedfusionofmetalsusingalaserbeam AT michaelfzaeh experimentalinvestigationsontheformationmechanismsofshrinklinesinpowderbedfusionofmetalsusingalaserbeam |