MSE 2024
Lecture
26.09.2024
Approaches for the manufacturing of parts via PBF-LB/M under vacuum atmosphere
SF

Steffen Fritz (M.Sc.)

Universität Stuttgart

Fritz, S. (Speaker)¹
¹University of Stuttgart
Vorschau
20 Min. Untertitel (CC)

Typically, in powder bed fusion of metals using a laser beam (PBF-LB/M) a shielding gas like Nitrogen or Argon is used to prevent oxidization. By circulating the shielding gas over the power bed and through a filter system spatter and metal condensate can efficiently be transported out of the process zone. However, in laser welding sub-atmospheric pressures are deliberately utilized, as they offer advantages in terms of process stability. Applying this concept to PBF-LB/M could lead to smaller manufacturing system periphery and less shielding gas consumption. However, for PBF-LB/M findings like in laser welding are lacking. Instead, it has proven to be exceedingly challenging to manufacture parts via PBF-LB/M under vacuum conditions. The main reason for this is an instability of the powder bed due to powder denudation. During the lecture, two distinct approaches to address this issue are presented, with both approaches employing a double scanning strategy. The first scanning aims at minimizing powder denudation, while the second scanning is used to ensure sufficient cohesion within one layer as well as to underlying layers. The main difference between the two approaches lies within the first scanning. For the first approach an interval scanning strategy is used, meaning that the scanning is completed in four passes and with every pass only every fourth line is scanned. For the second approach the laser beam is deliberately defocused in order to sinter powder particles much like in the process of powder bed fusion of metals using an electron beam (PBF-EB/M). Both approaches facilitate the manufacturing of cubicles and other specimens from steel powder via PBF-LB/M under pressures as low as 20 µbar. The relative density and mechanical properties of parts produced in a vacuum are compared with those produced under atmospheric pressure. This still reveals some differences between the various manufacturing conditions. Furthermore, additional issues are discussed due to the lack of gas circulation, which is normally responsible for the removal of by-products from the process zone. The results presented show disparities in quality between parts manufactured under vacuum and conventionally manufactured parts and further challenges to tackle, while clearly underscoring the potential of PBF-LB/M in vacuum environments.

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