Error Detection in Laser Beam Melting Systems by High Resolution Imaging

Laser Beam Melting as a member of Additive Manufacturing processes allows the fabrication of three-dimensional metallic parts with almost unlimited geometrical complexity and very good mechanical properties. However, its potential in areas of application such as aerospace or medicine has not yet been exploited due to the lack of process stability and quality management. For that reason samples with pre-defined process irregularities are built and the resulting errors are detected using high-resolution imaging. This paper presents an overview of typical process errors and proposes a catalog of measures to reduce process breakdowns. Based on this systematical summary a future contribution to quality assurance and process documentation is aspired.Mechanical Engineerin

Powder properties and flowability measurements of tailored nanocomposites for powder bed fusion applications

The modification of metal alloy powders by coating with nanoparticles offers the possibility to improve additive manufacturing processes, in particular the powder bed fusion of metals with laser beams (PBF/LB-M), from the material side of view. Subsequently, component qualities including mechanical properties and microstructural characteristics could be improved. Furthermore, the modification enables improved energy utilization due to an increase in laser absorption. In this work three commercial additive manufacturing powders, namely stainless steel (1.4404), tool steel (1.2709), and aluminum alloy (3.2381) were coated with three different nanoparticles (Silicon carbide (SiC), few layer graphene (FLG), and iron oxide black (IOB) to increase the laser light absorption in the PBF/LB/M process, mechanical properties, and flowability of the powders. The coating was conducted within a fluidized bed system, resulting in homogeneous coatings. This study demonstrates, that well scalable processes i.e. stirred media milling and fluidized bed coating have the potential to improve the commercial AM powders regarding their bulk density, flowability, and energy absorption, which is a crucial step towards an improvement in the efficiency of the whole PBF process. Overall important information and relations were gathered to transfer them to the real powder deposition process in future work