Nickel-based superalloys have great applications in the fabrication of turbine blades, jet engines, and other high-value metal components found in marine applications, industrial or nuclear reactors. Using additive manufacturing technology to build these components can offer significant benefits. However, the laser processability of these alloys shows they are prone to cracking.
Powder production routes, actual AM process and recycling methods all influence particles characteristics. In powder bed fusion, these properties affect the homogeneity and density of the powder layers spread across the build platform and, in turn, the process repeatability and the parts quality. Quantifying a combination of factors defining a ‘good’, process-able powder is still required for AM. Yet little has been studied to link traditional powder measurements to its flowability and to its AM process-specific spreading abilities. In this post, let’s discuss suitable parameters and values to qualify flowability of metal powders for selective laser melting (SLM).
Obtaining high density components is a trade-off between build rate and powder irradiation time (ie scanning speed). Achieving high density is usually the 1st step in parameters development for SLM and EBM. But do we have to assume (close to) 100% density to obtain satisfactory mechanical properties? This blog post addresses the impact of defects obtained in SLM on mechanical properties of Ti64.
Functionally graded materials (FGM) are designed materials tailored to exhibit as-built inhomogeneous compositions and microstructures. Since Laser Metal Deposition (LMD) uses various hoppers to supply powder feedstock at the laser focus, it has the ability to produce FGMs by selectively depositing different elemental powders into the molten pool at specific locations in the structure during part buildup [1,2].
Aluminium alloys are notoriously difficult materials to cast or weld. Their naturally high reactivity with the environment favours oxidation and moisture pick up that promotes pores formation during solidification. Among other mechanisms, gas porosity need to be addressed. In casting, this can be done by adjusting the cooling rate . In welding, it can be done by scanning the surface . This post addresses a few ways to decrease hydrogen porosity formed during Selective Laser Melting.
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