Description

The trajectory of metal additive manufacturing is transitioning from rapid prototyping towards on-demand and serial production. Consequently, the paramount objective remains the enhancement of additive manufacturing processes like laser-based powder bed fusion of metals (PBF-LB/M) to meet modern manufacturing needs and reduce environmental impact. Shielding gas flow significantly influences mechanical properties in PBF-LB/M by protecting metal from oxidation and removing process by-products from the powder melting zone. Accordingly, improper shielding gas flow distribution can result in poor part quality, excessive inert gas consumption, and contamination of the building chamber. Presently, a lack of consensus remains regarding which configuration of shielding gas supply is most appropriate in terms of process efficiency. This is the comprehensive investigation of a localized and vertically directed shielding gas flow and its effects on the properties of parts, also taking into account the reduction of inert gas consumption. In contrast to previous investigations, it is shown that enhanced surface roughness and relative density of the parts, as well as minimized contamination of the optics inside the building chamber is achieved through more efficient removal of metal plume particles from the processing zone by localized gas flow. Moreover, the developed computational fluid dynamics (CFD) simulation model enabled the efficient determination of particularly promising gas flow configurations. Furthemore, the validation of the simulation model is demonstrated in an experimental environment. Finally, by localizing shielding gas flow, energy consumption can be reduced by almost half.

Contributing Authors

  • Vadim Medvedev
    Bayerisches Laserzentrum GmbH | Erlangen Graduate School in Advanced Optical Technologies (SAOT)
  • Sebastian-Paul Kopp
    Bayerisches Laserzentrum GmbH | Erlangen Graduate School in Advanced Optical Technologies (SAOT) | Institute of Photonic Technologies (LPT)
  • Stephan Roth
    Bayerisches Laserzentrum GmbH | Erlangen Graduate School in Advanced Optical Technologies (SAOT)
Vadim Medvedev
Bayerisches Laserzentrum GmbH | Erlangen Graduate School in Advanced Optical Technologies (SAOT)
Track: Laser Additive Manufacturing
Session: Powder Bed Fusion I
Day of Week: Tuesday
Date/Time:
Location: Mt. Olympus

Keywords

  • Additive Manufacturing
  • Laser Based Powder Bed Fusion
  • Process By-Products
  • Process Efficiency
  • Shielding Gas Flow