Laser melting functionally graded composition of Waspaloy((R)) and Zirconia powders

An approach for fabricating functionally graded specimens of supernickel alloy and ceramic compositions via Selective Laser Melting (SLM) is presented. The focus aimed at using the Functionally Graded Material (FGM) concept to gradually grade powdered compositions of Zirconia within a base material of Waspaloy® . A high power Nd:YAG laser was used to process the material compositions to a high density with gradual but discrete changes between layered compositions. The graded specimens initially consisted of 100% Waspaloy® with subsequent layers containing increased volume compositions of Zirconia (0-10%). Specimens were examined for porosity and microstructure. It was found that specimens contained an average porosity of 0.34% with a gradual change between layers without any major interface defect

Customised Alloy Blends for In-Situ Al339 Alloy Formation Using Anchorless Selective Laser Melting

The additive manufacturing process Selective Laser Melting (SLM) can generate large thermal gradients during the processing of metallic powder; this can in turn lead to increased residual stress formation within a component. Metal anchors or support structures are required to be built during the process and forcibly hold SLM components to a substrate plate and minimise geometric distortion/warpage due to the process induced thermal residual stress. The requirement for support structures can limit the geometric freedom of the SLM process and increase post-processing operations. A novel method known as Anchorless Selective Laser Melting (ASLM) maintains processed material within a stress relieved state throughout the duration of a build. As a result, metal components formed using ASLM do not develop signification residual stresses within the process, thus, the conventional support structures or anchors used are not required to prevent geometric distortion. ASLM locally melts two or more compositionally distinct powdered materials that alloy under the action of the laser, forming into various combinations of hypo/hyper eutectic alloys with a new reduced solidification temperature. This new alloy is maintained in a semi-solid or stress reduced state for a prolonged period during the build with the assistance of elevated powder bed pre-heating. In this paper, custom blends of alloys are designed, manufactured and processed using ASLM. The purpose of this work is to create an Al339 alloy from compositionally distinct powder blends. The in-situ alloying of this material and ASLM processing conditions allowed components to be built in a stress-relieved state, enabling the manufacture of overhanging and unsupported features

Residual stress development in selective laser-melted Ti6Al4V: a parametric thermal modelling approach

High cooling rates within the Selective Laser Melting (SLM) process can generate large residual stresses within fabricated components. Understanding residual stress development in the process and devising methods for in-situ reduction continues to be a challenge for industrial users of this technology. Computationally efficient FEA models representative of the process dynamics (temperature evolution and associated solidification behaviour) are necessary for understanding the effect of SLM process parameters on the underlying phenomenon of residual stress build-up. The objective of this work is to present a new modelling approach to simulate the temperature distribution during SLM of Ti6Al4V, as well as the resulting melt pool size, solidification process, associated cooling rates and temperature gradients leading to the residual stress build-up. This work details an isotropic enhanced thermal conductivity model with the SLM laser modelled as a penetrating volumetric heat source. An enhanced laser penetration approach is used to account for heat transfer in the melt-pool due to Marangoni convection. Results show that the developed model was capable of predicting the temperature distribution in the laser/powder interaction zone, solidification behaviour, the associated cooling rates, melt-pool width (with 11% error) and melt-pool depth (with 3% error) for SLM Ti6Al4V. The model was capable of predicting the differential solidification behaviour responsible for residual stress build-up in SLM components. The model predicted trends in cooling rates and temperature gradients for varying SLM parameters, correlated with experimentally measured residual stress trends. Thus the model was capable of accurately predicting the trends in residual stress for varying SLM parameters. This is the first work based on the enhanced penetrating volumetric heat source, combined with an isotropic enhanced thermal conductivity approach. The developed model was validated by comparing FEA melt-pool dimensions with experimental melt-pool dimensions. Secondly the model was validated by comparing the temperature evolution along the laser scan path with experimentally measured temperatures from published literature

Transverse-momentum and pseudorapidity distributions of charged hadrons in pp collisions at √s=0.9 and 2.36 TeV

Measurements of inclusive charged-hadron transverse-momentum and pseudorapidity distributions are presented for proton-proton collisions at root s = 0.9 and 2.36 TeV. The data were collected with the CMS detector during the LHC commissioning in December 2009. For non-single-diffractive interactions, the average charged-hadron transverse momentum is measured to be 0.46 +/- 0.01 (stat.) +/- 0.01 (syst.) GeV/c at 0.9 TeV and 0.50 +/- 0.01 (stat.) +/- 0.01 (syst.) GeV/c at 2.36 TeV, for pseudorapidities between -2.4 and +2.4. At these energies, the measured pseudorapidity densities in the central region, dN(ch)/d eta vertical bar(vertical bar eta vertical bar and pp collisions. The results at 2.36 TeV represent the highest-energy measurements at a particle collider to date

AlSi12 In-Situ Alloy Formation and Residual Stress Reduction using Anchorless Selective Laser Melting

Rapid melt pool formation and solidification during the metal powder bed process Selective Laser Melting (SLM) generates large thermal gradients that can in turn lead to increased residual stress formation within a component. Metal anchors or supports are required to be built in-situ and forcibly hold SLM structures in place and minimise geometric distortion/warpage as a result of this thermal residual stress. Anchors are often costly, difficult and time consuming to remove and limit the geometric freedom of this Additive Manufacturing (AM) process. A novel method known as Anchorless Selective Laser Melting (ASLM) maintains processed material within a stress relieved state throughout the duration of a build. As a result metal components formed using ASLM do not require support structures or anchors. ASLM locally melts two or more powdered materials that alloy under the action of the laser and can form into various combinations of eutectic/hypo/hyper eutectic alloys with a new lower solidification temperature. This new alloy is maintained in a semi-solid or stress reduced state throughout the build with the assistance of elevated powder bed pre-heating. In this paper the ASLM methodology is detailed and investigations into processing of a low temperature eutectic Al-Si binary casting alloy is explored. Two types of Al powders were compared; pre-alloyed AlSi12 and elemental mix Al + 12 wt% Si. The study established an understanding of the laser in-situ alloying process and confirmed successful alloy formation within the process. Differential thermal analysis, microscopy and X-Ray diffraction were used to further understand the nature of alloying within the process. Residual stress reduction was observed within ASLM processed elemental Al + Si12 and geometries produced without the requirement for anchors

Selective laser melting of Inconel 625 using pulse shaping

Purpose – The purpose of this paper is to investigate the selective laser melting (SLM) of Inconel 625 using pulse shape control to vary the energy distribution within a single laser pulse. It aims to discuss the effectiveness of pulse shaping, including potential benefits for use within SLM. Design/methodology/approach – Laser parameters were varied in order to identify optimal parameters that produced thin wall parts with a low surface roughness without the use of pulse shape control. Pulse shape control was then employed to provide gradual heating or a prolonged cooling effect with a variety of peak power/pulse energy combinations. Properties of pulse shaped and nonpulse shaped parts were compared, with particular attention focused on part surface roughness and width. Findings – High peak powers tended to reduce top surface roughness and reduce side roughness as recoil pressures flatten out the melt pool and inhibit melt pool instabilities from developing. Ramp up energy distribution can reduce the maximum peak power required to melt material and reduce material spatter generation during processing due to a localized preheating effect. Ramp down energy distribution prolonged melt pool solidification allowing more time for molten material to redistribute, subsequently reducing the top surface roughness of parts. However, larger melt pools and longer solidification times increased the side roughness of parts due to a possible lateral expulsion of material from the melt pool. Originality/value – This paper is the first of its kind to employ laser pulse shape control during SLM to process material from powder bed. It is a useful aid in unveiling relationships between laser energy distribution and the formation of parts

Selective Laser Melting of Inconel 625 using Pulse Shaping

Pulse shaping is a technique used to temporally distribute energy within a single laser pulse. This allows the user to have an added degree of control over the heat delivered to the laser material interaction zone. Pulses that induce a gradual heating or a prolonged cooling effect can be generated with peak power/pulse energy combinations specifically tailored to control melt pool properties and eventual part formation. This investigation used a pulsed 550W Nd:YAG laser to melt 0.1mm layers of Inconel 625 from a powder bed. Initially a set of optimization experiments were completed to develop laser parameters that enabled the production of thin wall parts with low top and side surface roughness. Thin wall parts were then built using pulse shape control employing a variety of pulse energy distributions. Parts built with and without pulse shape control were measured for width, top and side surface roughness. The effectiveness of pulse shaping control is discussed including potential benefits for use within Selective Laser Melting (SLM)

Top surface and side roughness of Inconel 625 parts processed using selective laser melting

Purpose – Obtaining the required part top surface roughness and side roughness is critical in some applications. Each of these part properties can often be improved to the detriment of the other during selective laser melting (SLM). The purpose of this paper is to investigate the selective laser melting of Inconel 625 using an Nd:YAG pulsed laser to produce thin wall parts with an emphasis on attaining parts with minimum top surface and side surface roughness. Design/methodology/approach – A full factorial approach was used to vary process parameters and identify a usable Inconel 625 processing region. The effects laser process parameters had on the formation of part surface roughness for multi-layer parts were examined. Processing parameters that specifically affected top surface and side roughness were identified. Findings – Higher peak powers tended to reduce top surface roughness and reduce side roughness as recoil pressures flatten out the melt pool and reduce balling formation by increasing wettability of the melt. Increased repetition rate and reduced scan speed reduced top surface roughness but increased side roughness. A compromise between attaining a relatively low surface roughness and side roughness can be attained by comparing part surface roughness values and understanding the factors that affect them. A sample with 9mm top surface roughness and 10mm side roughness was produced. Originality/value – The research is the first of its kind directly processing Inconel 625 using SLM and investigating processing parameters that affect top surface and side roughness simultaneously. It is a useful aid in unveiling a relationship between process parameters and top/side roughness of thin walled parts

Selective Laser Melting of thin wall parts using pulse shaping

Pulse shaping is a technique used to temporally distribute energy within a single laser pulse. This provides the user an added degree of control over the heat delivered to the laser material interaction zone. Pulses that induce a gradual heating or a prolonged cooling effect can be generated with peak power/pulse energy combinations specifically tailored to control melt pool properties and eventual part formation. This investigation used a pulsed 550 W Nd:YAG laser to produce thin wall Inconel 625® parts using pulse shapes that delivered a variety of different energy distributions. Parts built with and without pulse shape control were measured for width, top and side surface roughness. The efficacy of pulse shaping control is discussed including potential benefits for use within the Selective Laser Melting process. Pulse shaping was shown to reduce spatter ejection during processing, improve the top surface roughness of parts and minimise melt pool width

High Density Selective Laser Melting of Waspaloy

In this work, high density Waspaloy® specimens were produced using specially assembled laboratory equipment by Selective Laser Melting (SLM). SLM of Waspaloy® powder was performed using a high power pulsed Nd:YAG laser. The laser parameters pulse energy (J), pulse width (ms), repetition rate (Hz) and scan speed (mm/min) were varied. Process parameter optimization was achieved using factorial analysis to investigate the relationship between specific processing parameters and the formation of Waspaloy® specimens. The optimized processing parameters produced Waspaloy® specimens that were 99.3 % dense. The resultant laser melted specimen’s height, width and contact angles were measured. Specimens were also observed for the occurrence of porosit