Efficient approach to manufacture 3D high density metal parts

Lawrence Livermore National Laboratory researchers have developed a new and more efficient approach to a challenging problem in additive manufacturing — using selective laser melting, namely, the selection of appropriate process parameters that result in parts with desired properties.

Selective laser melting (SLM) is a powder-based, additive manufacturing process where a 3D part is produced, layer by layer, using a high-energy laser beam to fuse the metal powder particles. Some SLM applications require parts that are very dense, with less than 1 percent porosity, as the pores or voids are the weakest part of the material and most likely would result in failure.

But building functional parts and components to specific standards and performance specifications can be challenging because a large number of parameters must be set appropriately. Some of the key parameters include laser power, laser speed, distance between laser scan lines, scanning strategy and powder layer thickness. As a result, there is a need for a reliable and cost-effective approach to determine the right parameters to develop parts with such desired properties as high density.

LLNL researchers have developed an efficient approach, based on simple simulations and experiments, to identify optimal parameters to print 3D high-density metal parts.

Direct metal laser melting (DMLM) machine in action: A laser fuses metal powder to form one of many successive layers that will form the final manufactured part.

The International Journal of Advanced Manufacturing Technology – Density of additively-manufactured, 316L SS parts using laser powder-bed fusion at powers up to 400 Watts

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