Studies on Effect of Process Parameters on Sintering of Materials Using Laser Assisted Powder Bed Fusion Process

Jayson P. Sequeira*, Vinay Pharale**, Preetham E.***, M.S. Krupashankara****
*-*** Postgraduate in Product Design and Manufacturing, R V College of Engineering, Bangalore, India.
**** Professor, Department of Mechanical Engineering at R V College of Engineering, Bangalore, India.
Periodicity:February - April'2018
DOI : https://doi.org/10.26634/jme.8.2.14208

Abstract

Additive Manufacturing (AM) is emerging as an innovative technology distinguished from traditional manufacturing techniques because of its ability to produce complex, fully functioning and end-use products with great design flexibility. This technology is going to have utmost impact on future manufacturing industries. In the present research study, among the seven AM processes, laser based powder bed fusion (L- PBF) or selective laser sintering is gaining more importance due to its capability to process both metals and non-metals starting from metals to polymer and ceramics. Most L-PBF machines are imported and expensive. Hence R V College of Engineering and KCTU (Karnataka Council for Technological Upgradation) - Government of Karnataka have jointly developed an indigenous L-PBF machine, which has been utilized to conduct studies on effect of processing parameters on sintering of iron, silicon carbide, and polyethylene powders. Three key process parameters, laser power, hatch spacing, and scan speed were chosen for this study. The experiments have been conducted according to L9 orthogonal array based on Taguchi methodology of design of experiments adopted to determine the optimum sintering conditions for each of the three materials. Iron powder was optimally sintered with a laser power of 90 W, scan speed of 500 mm/s, hatch spacing of 0.1 mm, at spot size of 0.5 mm. Silicon Carbide powders were sintered with a laser power of 20 W, scan speed of 25 mm/s, hatch spacing of 0.4 mm, at spot size of 1 mm. Polyethylene powders were sintered using a laser power of 22.5 W, hatch spacing of 0.3 mm, Scan speed of 500 mm/s, at spot size of 1.5 mm. The influence of these parameters on energy density was 3 determined. In order to produce iron parts, an energy density of 18 J/mm was required, while in case of Silicon carbide 3 3 parts, it was 21 J/mm and for polyethylene, it was 1.5 J/mm .

Keywords

CO Laser, Laser Process Parameters, Selective Laser Sintering.

How to Cite this Article?

Sequeira,J. S., Pharale,V., Preetham, E., and Krupashankara,M.S. (2018). Studies on Effect of Process Parameters on Sintering of Materials Using Laser Assisted Powder Bed Fusion Process. i-manager’s Journal on Mechanical Engineering, 8(2), 9-17. https://doi.org/10.26634/jme.8.2.14208

References

[1]. Bai, J., Zhang, B., Song, J., Bi, G., Wang, P., & Wei, J. (2016). The effect of processing conditions on the mechanical properties of polyethylene produced by selective laser sintering. Polymer Testing, 52, 89-93.
[2]. Calignano, F., Manfredi, D., Ambrosio, E. P., Biamino, S., Lombardi, M., Atzeni, E., ... & Fino, P. (2017). Overview on additive manufacturing technologies. Proceedings of the IEEE (Vol. 105(4), pp. 593-612).
[3]. Ghosh, S. K., Bandyopadhyay, K., & Saha, P. (2014). Development of an in-situ multi-component reinforced Albased metal matrix composite by direct metal laser sintering technique-Optimization of process parameters. Materials Characterization, 93, 68-78.
[4]. Gibson, I., Rosen, D. W., & Stucker, B. (2010). Additive Manufacturing Technologies. Springer, New York.
[5]. Goodridge, R. D., Hague, R. J., & Tuck, C. J. (2010). An empirical study into laser sintering of Ultra-High Molecular Weight Polyethylene (UHMWPE). Journal of Materials Processing Technology, 210(1), 72-80.
[6]. Goodridge, R. D., Shofner, M. L., Hague, R. J. M., McClelland, M., Schlea, M. R., Johnson, R. B., & Tuck, C. J. (2011). Processing of a Polyamide-12/carbon nanofibre composite by laser sintering. Polymer Testing, 30(1), 94- 100.
[7]. Lee, H., Lim, C. H. J., Low, M. J., Tham, N., Murukeshan, V. M., & Kim, Y. J. (2017). Lasers in additive manufacturing: A review. International Journal of Precision Engineering and Manufacturing-Green Technology, 4(3), 307-322.
[8]. Pinker ton, A. J. (2016). Lasers in additive manufacturing. Optics & Laser Technology, 78, 25-32.
[9]. Schmidt, M., Merklein, M., Bourell, D., Dimitrov, D., Hausotte, T., Wegener, K., ... & Levy, G. N. (2017). Laser based additive manufacturing in industry and academia. CIRP Annals, 66(2), 561-583.
[10]. Shahzad, K., Deckers, J., Zhang, Z., Kruth, J. P., & Vleugels, J. (2014). Additive manufacturing of Zirconia parts by indirect selective laser sintering. Journal of the European Ceramic Society, 34(1), 81-89.
[11]. Uhlmann, E., Bergmann, A., & Gridin, W. (2015). Investigation on Additive Manufacturing of Tungsten Carbide-Cobalt by Selective Laser Melting. Procedia CIRP, 35, 8-15.
[12]. Wong, K. V., & Hernandez, A. (2012). A review of additive manufacturing. International Scholarly Research Network ISRN Mechanical Engineering 2012, Article ID 208760, 1-10. doi:10.5402/2012/208760.
[13]. Zhou, X., Liu, X., Zhang, D., Shen, Z., & Liu, W. (2015). Balling phenomena in selective laser melted Tungsten. Journal of Materials Processing Technology, 222, 33-42.

Purchase Instant Access

Single Article

North Americas,UK,
Middle East,Europe
India Rest of world
USD EUR INR USD-ROW
Pdf 35 35 200 20
Online 35 35 200 15
Pdf & Online 35 35 400 25

If you have access to this article please login to view the article or kindly login to purchase the article
Options for accessing this content:
  • If you would like institutional access to this content, please recommend the title to your librarian.
    Library Recommendation Form
  • If you already have i-manager's user account: Login above and proceed to purchase the article.
  • New Users: Please register, then proceed to purchase the article.