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The effect of processing parameters and material properties on residual forces induced in LPBF The effect of processing parameters and material properties on residual forces induced in LPBF
The effect of processing parameters and material properties on residual forces induced in LPBF
The effect of processing parameters and material properties on residual forces induced in LPBF
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From the DIC measurements of the out-of-plane deformation shown in Fig. 15, it can be observed the part deformation for the maraging steel built in argon gas created a convex shape relative to the laser and was both the opposite to and only about 20% of the deformation in the other materials that formed a concave shape. A reduction in the energy input into the part, either by reducing the laser power (Figs. 7 and 8) or by increasing the point distance (Figs. 9 and 10), resulted in a reduction in the forces induced in the part and in both cases the changes observed were not proportional to the changes in the process parameter. In other words, there was no significant difference between the forces measured using values of 180 W and 200 W for laser power or values of 70 m and 80 m for point distance; however, a laser power of 160 W produced a step decrease in measured forces, and a point distance of 60 m gave a step increase in the forces. Thus, the processing parameters and energy input should be carefully selected to ensure complete fusion of the metal powder particles, in order to reduce porosity and achieve complete bonding between layers; while avoiding excess energy input that will increase residual stresses by increasing the size of the melt pool and the heated affected zone [43]. This is likely associated with the allotropic phase transformation between martensite and austenite that occurs in maraging steel which cause complex changes in the microstructure during L-PBF and during subsequent thermal cycles caused by scanning adjacent to the recently formed material [40].
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1 From the DIC measurements of the out-of-plane deformation shown in Fig. 15, it can be observed the part deformation for the maraging steel built in argon gas created a convex shape relative to the laser and was both the opposite to and only about 20% of the deformation in the other materials that formed a concave shape. 2 A reduction in the energy input into the part, either by reducing the laser power (Figs. 7 and 8) or by increasing the point distance (Figs. 9 and 10), resulted in a reduction in the forces induced in the part and in both cases the changes observed were not proportional to the changes in the process parameter. 3 In other words, there was no significant difference between the forces measured using values of 180 W and 200 W for laser power or values of 70 m and 80 m for point distance; however, a laser power of 160 W produced a step decrease in measured forces, and a point distance of 60 m gave a step increase in the forces. 4 Thus, the processing parameters and energy input should be carefully selected to ensure complete fusion of the metal powder particles, in order to reduce porosity and achieve complete bonding between layers; while avoiding excess energy input that will increase residual stresses by increasing the size of the melt pool and the heated affected zone [43]. 5 This is likely associated with the allotropic phase transformation between martensite and austenite that occurs in maraging steel which cause complex changes in the microstructure during L-PBF and during subsequent thermal cycles caused by scanning adjacent to the recently formed material [40].