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Metallic Solids02:37

Metallic Solids

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Metallic solids such as crystals of copper, aluminum, and iron are formed by metal atoms. The structure of metallic crystals is often described as a uniform distribution of atomic nuclei within a “sea” of delocalized electrons. The atoms within such a metallic solid are held together by a unique force known as metallic bonding that gives rise to many useful and varied bulk properties.
All metallic solids exhibit high thermal and electrical conductivity, metallic luster, and malleability....
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Dual-Laser PBF-LB Processing of a High-Performance Maraging Tool Steel FeNiCoMoVTiAl.

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PBF-LB Process-Induced Regular Cavities for Lightweight AlSi10Mg Structures.

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Researchers developed a new method for powder bed fusion with laser beam (PBF-LB) to create parts with up to 60% porosity using the balling effect. This process-controlled technique enables reproducible manufacturing of regularly distributed cavities without pre-processing.

Keywords:
aluminumprocess controlselective laser melting (SLM)

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Area of Science:

  • Materials Science
  • Additive Manufacturing
  • Mechanical Engineering

Background:

  • Powder Bed Fusion with Laser Beam (PBF-LB) typically results in limited porosity (~13%) due to keyhole and lack-of-fusion defects.
  • Existing defects are heterogeneously distributed, limiting their application in lightweight or damping designs.
  • Digital pre-processing is currently required for targeted defect creation.

Purpose of the Study:

  • To present a novel process-controlled method for manufacturing parts with controlled porosity.
  • To demonstrate the use of the balling effect for targeted cavity formation.
  • To achieve higher and regularly distributed porosity levels compared to conventional PBF-LB.

Main Methods:

  • Utilizing the balling effect in PBF-LB for controlled pore formation.
  • Implementing a process-controlled strategy for reproducible manufacturing.
  • Testing the method with AlSi10Mg material.

Main Results:

  • Achieved reproducible manufacturing of solid parts with regularly distributed cavities.
  • Reached up to 60% porosity in AlSi10Mg samples.
  • Eliminated the need for time-consuming digital pre-processing.

Conclusions:

  • The novel process-controlled method enables targeted and reproducible manufacturing of highly porous parts using the balling effect in PBF-LB.
  • This technique offers a significant advancement over conventional methods, allowing for higher porosity levels and eliminating pre-processing steps.
  • The developed approach opens new avenues for lightweight and damping applications in additive manufacturing.