Optimized process parameters are essential for successful additive manufacturing, where the parameters must be optimized for the intended component / product. First, the significant parameters are optimized for smaller test objects, which are then transferred to the specific component. That provides a cost-effective and quality-assured AM.
RISE can offer process parameter optimization for existing materials, as well as for newly developed materials, when manufacturing of bulk material via laser powder bed fusion. A number of significant process parameters are varied and combined during manufacturing trials. This is followed by characterization of specimens, which can for example include microstructure evaluation, surface topography analyses, hardness, residual stress evaluation, mechanical testing as well as corrosion properties. Which characterization that are suitable for the specific activity, will be discussed before the work starts. This iterative process can be offered through any of the three listed solutions:
A number of significant process parameters for manufacturing of bulk material are selected for experimental trials. The test matrix is set up according to a linear design of experiments model where each point in the matrix corresponds to a manufactured specimen. The response measured and evaluated after manufacturing is usually density, percentage of defects and hardness, but not limited to. Evaluation takes place with the help of design of experiment theory.
When a functional process window is identified, a quadratic optimization model is applied in the next step for further experiments. In this step, the process parameters that have proved significant in the previous step are varied within the functional process window. The purpose is usually to optimize the process parameters with respect to low percentage of defects. Once the process parameters have been found for smaller test objects, they can be transferred to larger parts to evaluate the outcome. Depending on the outcome, potentially additional loops might be needed.
The results are delivered according to agreement but usually in the form of a written report together with optimized process parameters.
This is one of many services included in the Application center for additive manufacturing. For more information visit:
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Parametric development for powder bed fusion of metallic materials
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