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Three-Dimensional Particle Shape Analysis Using X-ray Computed Tomography: Experimental Procedure and Analysis Algorithms for Metal Powders

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Concentric Scanning Strategies for Laser Powder Bed Fusion: Porosity Distribution in Practical Geometries.

Lukas Englert¹, Volker Schulze¹, Stefan Dietrich¹

¹Karlsruhe Institute of Technology, Institute for Applied Materials (IAM-WK), Engelbert-Arnold-Straße 4, 76131 Karlsruhe, Germany.

Materials (Basel, Switzerland)

|February 15, 2022

Summary

Optimizing laser powder bed fusion (LPBF) with advanced scan paths reduces laser downtime and potential defects. However, new strategies require careful design to manage porosity and part geometry interactions.

Keywords:

G-code SLM build job micro-computed tomography toolpath

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Area of Science:

Additive Manufacturing
Materials Science
Mechanical Engineering

Background:

Traditional laser powder bed fusion (LPBF) hatching strategies, while ensuring microstructural homogeneity, suffer from frequent laser on/off switching and increased susceptibility to keyhole pores at scan vector endpoints.
These limitations can significantly slow down the fabrication process and compromise part integrity.

Purpose of the Study:

To investigate advanced scan strategies for LPBF that utilize longer scan paths to minimize laser switching and reduce end-of-track defect formation.
To develop and integrate an open-source tool for customizing LPBF G-code based on part geometry and advanced path configurations.

Main Methods:

Development of an open-source G-code tailoring tool integrated into a co-visualization platform.
Fabrication of specimens using four distinct scan path strategies, including a spiral pattern.
Analysis of pore distribution and path neighborhood effects using micro-computed tomography.

Main Results:

A spiral scan pattern reduced laser jump distance by 78% in the example geometry.
Alternative path patterns demonstrated a strong dependence of defect architecture on part geometry.
The investigated alternative path patterns led to an increase in overall porosity to 0.42%.

Conclusions:

Advanced scan strategies offer potential for optimizing LPBF by reducing laser downtime, but their effectiveness is highly dependent on part geometry.
Increased porosity observed with alternative paths necessitates the development of specific alleviation approaches.
Further research is required to balance the benefits of reduced laser switching with the control of defect formation in LPBF.