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Powder Spreading Mechanism in Laser Powder Bed Fusion Additive Manufacturing: Experiments and Computational Approach

Ummay Habiba1, Rainer J Hebert1

  • 1Department of Materials Science and Engineering, Institute of Materials Science, University of Connecticut, Storrs, CT 06269-3136, USA.

Materials (Basel, Switzerland)
|April 13, 2023
PubMed
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This summary is machine-generated.

This study investigates how input parameters affect powder spreading in laser powder bed fusion (LPBF) additive manufacturing (AM). Discrete element method (DEM) simulations reveal impacts on powder density and particle distribution for improved part quality.

Area of Science:

  • Materials Science
  • Mechanical Engineering
  • Manufacturing Technology

Background:

  • Laser powder bed fusion (LPBF) is a key additive manufacturing (AM) technology.
  • Effective powder spreading is critical for high-quality LPBF parts.
  • Understanding powder behavior influences process optimization.

Purpose of the Study:

  • Investigate the impact of input parameters on powder spreading in LPBF.
  • Analyze powder density and particle distribution during the spreading process.
  • Correlate simulation results with experimental measurements.

Main Methods:

  • Utilized Discrete Element Method (DEM) simulations for powder spreading analysis.
  • Simulated multiple powder layers to assess packing density variations.
Keywords:
ESI softwareadditive manufacturing (AM)discrete element method (DEM)laser powder bed fusion (LPBF)metal powderparticle size distributionparticle trajectoryporositypowder bed packing densitypowder spreadingspreader velocity

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  • Conducted experimental measurements of powder packing density and particle size distribution.
  • Main Results:

    • DEM simulations demonstrated variations in powder particle packing density across layers and along the spreading direction.
    • Input parameters significantly influence powder density and particle distribution.
    • Experimental data validated simulation findings on powder packing and particle size.

    Conclusions:

    • Optimizing input parameters in LPBF powder spreading is essential for consistent part quality.
    • DEM simulations provide valuable insights into powder dynamics for process improvement.
    • Further research can leverage these findings for advanced AM process control.