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Defect Prevention in Selective Laser Melting Components: Compositional and Process Effects.

Hossein Eskandari Sabzi1, Pedro E J Rivera-Díaz-Del-Castillo1

  • 1Department of Engineering, Lancaster University, Gillow Ave, Bailrigg, Lancaster LA1 4YW, UK.

Materials (Basel, Switzerland)
|November 23, 2019
PubMed
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This study presents a thermodynamic model to predict and prevent defects in 3D metal printing, ensuring crack-free parts and optimal alloy design for selective laser melting processes.

Area of Science:

  • Materials Science and Engineering
  • Additive Manufacturing
  • Thermodynamics

Background:

  • Additive manufacturing (AM), particularly selective laser melting (SLM), faces challenges with defect formation, impacting material integrity.
  • Key defects include cracks, keyholes, balling, and lack of fusion, which are critical to prevent for reliable part production.
  • Existing models often lack comprehensive prediction capabilities for these diverse defects under varying process conditions.

Purpose of the Study:

  • To develop a predictive model for assessing 3D metal printing printability.
  • To focus on preventing critical defects: cracks, keyholes, balls, and lack of fusion.
  • To provide insights for alloy design and SLM process optimization.

Main Methods:

  • Utilized thermodynamics and physical analysis as the core of the predictive model.
Keywords:
additive manufacturingaustenitic stainless steelporositysolidification cracking

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  • Incorporated control of solidification temperature range and path for crack prevention.
  • Quantified resistance to thermal stresses during solidification.
  • Controlled melt pool geometry and considered melting properties for defect prevention.

    • Main Results:

    • The model accurately predicts conditions leading to crack formation.
    • It effectively identifies parameters to avoid defects like keyholes, balls, and lack of fusion.
    • Demonstrated accurate prediction of defect formation in 316L austenitic stainless steel.

    Conclusions:

    • The developed thermodynamic model offers a robust approach to ensuring printability in AM.
    • It provides crucial information for optimizing alloy composition and SLM process parameters.
    • The model serves as a valuable tool for achieving high-quality, defect-free metal parts.