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Updated: May 7, 2025

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Effective Spiral Laser Path for Minimizing Local Heating and Anisotropic Microstructures in Powder Bed Fusion

Jeongho Yang1,2, Seong Je Park3, Sang Hoon Kim4

  • 1Additive Manufacturing Innovation Agency, Korea Institute of Industrial Technology, Siheung-si, Korea.

3D Printing and Additive Manufacturing
|December 30, 2024
PubMed
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A new spiral laser path significantly reduces heat buildup and thermal deformation in powder bed fusion (PBF) additive manufacturing. This optimized path leads to higher precision and less residual stress in 3D printed parts.

Area of Science:

  • Additive Manufacturing
  • Materials Science
  • Computational Fluid Dynamics

Background:

  • Heat accumulation during repetitive laser processing in powder bed fusion (PBF) causes high residual stress and thermal deformation.
  • Optimizing laser paths is crucial for managing thermal dispersion and mitigating these issues.

Purpose of the Study:

  • To develop and validate a novel laser path strategy for PBF additive manufacturing.
  • To minimize local heating and reduce thermal deformation and residual stress in 3D printed structures.

Main Methods:

  • Computational fluid dynamics (CFD) analysis using the volume of fraction method to simulate heat accumulation.
  • Proposal and comparison of a novel spiral laser path against conventional scanning paths.
  • Experimental evaluation of thermal deformation on a cantilever structure fabricated using the optimized spiral path.
Keywords:
additive manufacturing (AM)computational fluid dynamics (CFD)local heat accumulationpowder bed fusion (PBF)spiral laser scanning paththermal deformation

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Related Experiment Videos

Last Updated: May 7, 2025

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Main Results:

  • The optimal spiral laser path reduced accumulated temperature by 200.9 K compared to general repetitive paths.
  • Experimental tests showed a 52.3% reduction in thermal deformation with the spiral path versus a one-directional path.
  • The spiral path resulted in less residual stress and more uniform microstructure.

Conclusions:

  • The proposed spiral laser path effectively minimizes heat accumulation and thermal deformation in PBF.
  • This optimized laser path strategy enhances precision and material quality in additive manufacturing.
  • Numerical simulations and experimental validation confirm the benefits of the spiral laser path for PBF processes.