Characterization and recyclability of 304L stainless steel powder for use in the selective laser melting process

Powder-bed fusion refers to a subset of additive manufacturing (AM) methods which successively melts and solidifies selected regions within a powder bed on a layer-by-layer basis to construct components directly from computer-aided design files. Laser Powder-Bed Fusion (L-PBF) is a process among the powder-bed fusion techniques that utilizes a laser to consolidate particles into a material with little porosity. During the L-PBF process, the large energy input from the laser causes the production of ejecta in the form of laser spatter and condensate, both of which have the potential to settle in the surrounding powder bed compromising its reusability. In order to better understand the impact of ejecta on powder recyclability, samples of 304L laser spatter and condensate were characterized in terms of morphology, chemistry, and microstructure. Differences between ejecta and virgin powder were used as a basis for understanding the evolution in 304L powder properties with reuse in the L-PBF process over the course of 7 iterations, which revealed an improvement in flowability with recycling. The effects of evolving powder properties on the tensile and impact toughness properties were also assessed for capturing possible deterioration in mechanical performance. Due to the improvement in powder flowability during recycling, the effects of alterations in the particle size were further investigated using the Discrete Element Method (DEM). Through development of a mathematical definition of spreadability, differences in the particle size distribution as well as recoating velocity and layer thickness revealed changes in the powder-bed quality providing crucial knowledge of the mechanisms behind the powder spreading process --Abstract, page iv

Bonding of 304L Stainless Steel to Cast Iron by Selective Laser Melting

While cast iron is widely used in industry, a major limitation is the weldability of a dissimilar material onto cast iron due to hot cracking as a result of lack of ductility from graphite flakes. Consequently, a significant amount of preheat is often employed to reduce the cooling rate in the fusion zone, which, however, may lead to distortion of the welded parts. A potential remedy could be the Selective Laser Melting (SLM) process, where only small melt pools are created and thus the overall energy input is reduced. The present paper describes an investigation of the SLM process to join 304L stainless steel with cast iron. In this study, 304L stainless steel particles ranging from 15-45 μm in size were melted on a grey cast iron substrate by the SLM process. Multiple sets of parameter values were chosen to test different energy densities on the tensile strength of the bond created. Subsequent characterization of the bonded area included energy dispersive spectroscopy (EDS) mapping for obtaining insight into the elemental diffusion, and metallography for visualization of the microstructure. A range of energy densities was identified for purposes of eliminating bond delamination and maximizing mechanical strength

Experimental Approach for Development of a Powder Spreading Metric in Additive Manufacturing

The Powder Spreading is a Vital Step of Powder-Based Additive Manufacturing (AM) Processes. the Quality of Spread Powder Can Considerably Influence the Properties of Fabricated Parts. Poorly Packed Powder Beds with High Surface Roughness Result in Printed Part Layers with Large Porosity and Low Dimensional Accuracy, Leading to Poor Mechanical Properties. Therefore, the Powder Spread ability and its Dependence on Process Parameters and Powder Characteristics Should Be Quantified to Improve the Efficiency of Powder-Based AM Methods. This Study Proposes a Novel Dimensionless Powder Spread Ability Metric that Can Be Commonly Used in Different Powder-Based AM Processes. the Quality of Spread Powder in Terms of Powder Bed Density and Surface Roughness Was Evaluated by Adjusting the Process Parameters Including Recoating Velocity and Layer Thickness, and Powder Characteristics Including Particle Size Distribution. in Addition, the Dynamic Repose Angle Was Proposed and Examined as Another Powder Spread Ability Metric. the Results Showed that These Two Proposed Metrics Were Strongly Correlated and Lower Recoating Velocity and Larger Layer Thickness Led to Higher Spread ability and Lower Dynamic Repose Angle

Additive Manufacturing of Metal Bandpass Filters for Future Radar Receivers

Selective laser melting (SLM) is a powder-bed fusion (PBF) process that bonds successive layers of powder with a laser to create components directly from computer-aided design (CAD) files. The additive nature of the SLM process in addition to the use of fine powders facilitates the construction of complex geometries, which has captured the attention of those involved in the design of bandpass filters for radar applications. However, a significant drawback of SLM is its difficulty in fabricating parts with overhangs necessitating the use of support structures, which, if not removed, can greatly impact the performance of bandpass filters. Therefore, in this study bandpass filters are manufactured in two stages with 304L stainless steel where each builds only a portion of the part to improve the reliability in manufacturing the overhangs present. The results show that the versatility of SLM can produce difficult-to-manufacture bandpass filters with high dimensional accuracy

Recyclability of 304L Stainless Steel in the Selective Laser Melting Process

During part fabrication by selective laser melting (SLM), a powder-bed fusion process in Additive Manufacturing (AM), a large amount of energy is input from the laser into the melt pool, causing generation of spatter and condensate, both of which have the potential to settle in the surrounding powder-bed compromising its reusability. In this study, 304L stainless steel powder is subjected to five reuses in the SLM process to assess its recyclability through characterization of both powder and mechanical properties. Powder was characterized morphologically by particle size distribution measurements, oxygen content with inert gas fusion analysis, and phase identification by X-ray diffraction. The evolution of powder properties with reuse was also correlated to tensile properties of the as-built material. The results show that reused powder coarsens and accrues more oxygen with each reuse. The effects of powder coarsening and oxygen increase on the tensile properties of fabricated parts are being investigated

Design of Lattice Structures with Graded Density Fabricated by Additive Manufacturing

Lattice structures fabricated by Additive Manufacturing (AM) processes are promising for many applications, such as lightweight structures and energy absorbers. However, predicting and controlling of their mechanical behaviors is challenging due to the complexity of modeling and the uncertainties exist in the manufacturing process. In this paper, we explore the possibilities enabled by controlling the local densities. A set of lattice structures with different density gradients are designed using an implicit isosurface equation, and they are manufactured by Selective Laser Melting (SLM) process with 304L stainless steel. Finite element analysis and compression test are used to evaluate their mechanical properties. The results demonstrate the strong correlations between the structural gradient and the mechanical behavior. Introducing the density gradient provides more possibilities in the design phase, which can be used to further customize the design both structurally and functionally

Investigation of Mechanical Properties of Parts Fabricated with Gas- and Water-Atomized 304L Stainless Steel Powder in the Laser Powder Bed Fusion Process

The use of gas-atomized powder as the feedstock material for the laser powder bed fusion (LPBF) process is common in the additive manufacturing (AM) community. Although gas-atomization produces powder with high sphericity, its relatively expensive production cost is a downside for application in AM processes. Water atomization of powder may overcome this limitation due to its low-cost relative to the gas-atomization process. In this work, gas- and water-atomized 304L stainless steel powders were morphologically characterized through scanning electron microscopy (SEM). The water-atomized powder had a wider particle size distribution and exhibited less sphericity. Measuring powder flowability using the Revolution Powder Analyzer (RPA) indicated that the water-atomized powder had less flowability than the gas-atomized powder. Through examining the mechanical properties of LPBF fabricated parts using tensile tests, the gas-atomized powder had significantly higher yield tensile strength and elongation than the water-atomized powder; however, their ultimate tensile strengths were not significantly different

How do individuals' health behaviours respond to an increase in the supply of health care? Evidence from a natural experiment

AbstractThe efficacy of the management of long-term conditions depends in part on whether healthcare and health behaviours are complements or substitutes in the health production function. On the one hand, individuals might believe that improved health care can raise the marginal productivity of their own health behaviour and decide to complement health care with additional effort in healthier behaviours. On the other hand, health care can lower the cost of unhealthy behaviours by compensating for their negative effects. Individuals may therefore reduce their effort in healthier lifestyles. Identifying which of these effects prevails is complicated by the endogenous nature of treatment decisions and individuals’ behavioural responses. We explore whether the introduction in 2004 of the Quality and Outcomes Framework (QOF), a financial incentive for family doctors to improve the quality of healthcare, affected the population’s weight, smoking and drinking behaviours by applying a sharp regression discontinuity design to a sample of 32,102 individuals in the Health Survey for England (1997–2009). We find that individuals with the targeted health conditions improved their lifestyle behaviours. This complementarity was only statistically significant for smoking, which reduced by 0.7 cigarettes per person per day, equal to 18% of the mean. We investigate whether this change was attributable to the QOF by testing for other discontinuity points, including the introduction of a smoking ban in 2007 and changes to the QOF in 2006. We also examine whether medication and smoking cessation advice are potential mechanisms and find no statistically significant discontinuities for these aspects of health care supply. Our results suggest that a general improvement in healthcare generated by provider incentives can have positive unplanned effects on patients’ behaviours