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Updated: Jul 7, 2025
Production of Single Tracks of Ti-6Al-4V by Directed Energy Deposition to Determine the Layer Thickness for Multilayer Deposition
Published on: March 13, 2018
Process Parameter Optimization for Laser Powder Bed Fusion of Fe-Si Alloy Considering Surface Morphology and Track
Ho Sung Jang1,2, Su Heon Kim1,2, Geon-Woo Park3,4
1Advanced Forming Process R&D Group, Korea Institute of Industrial Technology, Ulsan 44776, Republic of Korea.
Abstract:
A laser power bed fusion (L-PBF) manufacturing process was optimized by analyzing the surface morphology and track width w of single scan tracks (SSTs) on Fe-3.4wt.%Si. An SST was evaluated under process conditions of laser power P, scan speed V, and energy density E = P/V. The SST surface shape was mainly affected by E; desirable thin and regular tracks were obtained at E = 0.3 and 0.4 J/mm. An L-PBF process window was proposed considering the optimal w of SST, and the appropriate range of E for the alloy was identified to be 0.24 J/mm to 0.49 J/mm. w showed a strong relationship with E and V, and an analytic model was suggested. To verify the process window derived from the appropriate w of SST, cubic samples were manufactured with the estimated optimal process conditions. Most samples produced had a high density with a porosity of <1%, and the process window derived from SST w data had high reliability. This study presents a comprehensive approach to enhancing additive manufacturing for Fe-3.4Si alloy, offering valuable insights for achieving high-quality samples without the need for time-intensive procedures.
