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Fabricating Inner Channels in Laser Additive Manufacturing Process via Thin-Plate-Preplacing Method
Junke Jiao1, Shengyuan Sun1, Zifa Xu2
1School of Mechanical Engineering, Yangzhou University, Yangzhou 225009, China.
Materials (Basel, Switzerland)
|October 14, 2023
Summary
This study introduces a hybrid manufacturing process combining laser packaging and Direct Metal Laser-Sintering (DMLS) to create complex parts with superior surface quality. This innovative method enhances microchannel fabrication by reducing defects and improving finish.
Area of Science:
- Manufacturing Engineering
- Materials Science
- Additive Manufacturing
Background:
- Complex cavity structures present manufacturing challenges, particularly regarding surface quality and internal defect control.
- Direct Metal Laser-Sintering (DMLS) is a key additive manufacturing technique, but often struggles with powder adhesion and surface finish in intricate internal features.
Purpose of the Study:
- To develop and validate a hybrid manufacturing process for producing complex cavity structures with high surface quality.
- To address limitations of traditional DMLS, specifically poor surface finish and powder contamination in closed inner cavities and microchannels.
Main Methods:
- A hybrid approach integrating laser precision packaging for component assembly with Direct Metal Laser-Sintering (DMLS) for part shaping.
- Investigated the morphology and microstructure of components produced via laser encapsulation and DMLS.
Main Results:
- Achieved a strong metallurgical bond between the thin plate and substrate using laser precision packaging.
- Attained a minimum surface roughness of 1.18 μm on DMLS molded parts.
- Optimized laser power at 240 W for improved perpendicularity in microchannel structures.
- Successfully eliminated powder sticking defects within the DMLS microchannels.
Conclusions:
- The hybrid manufacturing process effectively resolves issues of poor surface quality and powder contamination in closed inner cavities.
- This method significantly improves the finish of DMLS microchannels, enabling processing of internal features previously inaccessible to mechanical tools.
- Provides a foundational process for high-quality microchannel fabrication using DMLS.
