%0 Journal Article %1 Leis2021Process %A Leis, Artur %A Weber, Rudolf %A Graf, Thomas %D 2021 %I MDPI AG %J Materials %K PBF-LB/M SLM additive additivemanufacturing efficiency gsame laser lpbf myown peer %N 18 %P 5255 %R 10.3390/ma14185255 %T Process Window for Highly Efficient Laser-Based Powder Bed Fusion of AlSi10Mg with Reduced Pore Formation %U https://doi.org/10.3390%2Fma14185255 %V 14 %X The process window for highly efficient laser-based powder bed fusion (LPBF), ensuring the production of parts with low porosity, was determined by analyzing cross-sections of samples that were generated with laser powers varying between 10.8 W and 1754 W, laser beam diameters varying between 35 µm and 200 µm, and velocities of the moving laser beam ranging between 0.7 m/s and 1.3 m/s. With these parameters, the process alters between different modes that are referred to as simple heating, heat conduction melting (HCM), key-bowl melting (KBM), and deep-penetration melting (DPM). It was found that the optimum process window for a highly efficient LPBF process, generating AlSi10Mg parts with low porosity, is determined by the ratio P_L/d_b of the incident laser power P_L and the beam diameter d_b of the beam on the surface of the bead, and ranges between P_L/d_b = 2000 W/mm and P_L/d_b = 5200 W/mm, showing process efficiencies of about 7–8%. This optimum process window is centered around the range P_L/d_b = 3000–3500 W/mm, in which the process is characterized by KBM, which is an intermediate process mode between HCM and DPM. Processes with P_L/d_b < 2000 W/mm partially failed, and lead to balling and a lack of fusion, whereas processes with P_L/d_b > 5200 W/mm showed a process efficiency below 5% and pore ratios exceeding 10%.

@article{Leis2021Process, abstract = {The process window for highly efficient laser-based powder bed fusion (LPBF), ensuring the production of parts with low porosity, was determined by analyzing cross-sections of samples that were generated with laser powers varying between 10.8 W and 1754 W, laser beam diameters varying between 35 µm and 200 µm, and velocities of the moving laser beam ranging between 0.7 m/s and 1.3 m/s. With these parameters, the process alters between different modes that are referred to as simple heating, heat conduction melting (HCM), key-bowl melting (KBM), and deep-penetration melting (DPM). It was found that the optimum process window for a highly efficient LPBF process, generating AlSi10Mg parts with low porosity, is determined by the ratio P_L/d_b of the incident laser power P_L and the beam diameter d_b of the beam on the surface of the bead, and ranges between P_L/d_b = 2000 W/mm and P_L/d_b = 5200 W/mm, showing process efficiencies of about 7–8%. This optimum process window is centered around the range P_L/d_b = 3000–3500 W/mm, in which the process is characterized by KBM, which is an intermediate process mode between HCM and DPM. Processes with P_L/d_b < 2000 W/mm partially failed, and lead to balling and a lack of fusion, whereas processes with P_L/d_b > 5200 W/mm showed a process efficiency below 5% and pore ratios exceeding 10%.}, added-at = {2021-09-14T06:45:46.000+0200}, author = {Leis, Artur and Weber, Rudolf and Graf, Thomas}, biburl = {https://puma.ub.uni-stuttgart.de/bibtex/2f382ef9e4b918080d4123b00a1c54085/arturleis}, doi = {10.3390/ma14185255}, interhash = {ee1625725c6aa7ff0857defba405b65b}, intrahash = {f382ef9e4b918080d4123b00a1c54085}, journal = {Materials}, keywords = {PBF-LB/M SLM additive additivemanufacturing efficiency gsame laser lpbf myown peer}, month = sep, number = 18, pages = 5255, publisher = {MDPI AG}, timestamp = {2021-09-14T05:00:47.000+0200}, title = {Process Window for Highly Efficient Laser-Based Powder Bed Fusion of {AlSi}10Mg with Reduced Pore Formation}, url = {https://doi.org/10.3390%2Fma14185255}, volume = 14, year = 2021 }