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Prepared by_ Vedant Vyas.

(150180708011)
M.E. CAD/CAM.
Guided by_ Prof. R. I. Patel.
Place- GEC- Dahod.
PRESENTATION HIGHLIGHTES :
 Introduction.

 Process.

 Advantages.

 Limitations.

 Applications.

 Recent developments.
INTRODUCTION :

 Laser Powder Forming, also known by the proprietary name Laser


engineered net shaping is an additive manufacturing technology.

 For fabricating metal parts directly from a computer-aided


design (CAD) solid model by using a metal powder injected into a
molten pool created by a focused, high-powered laser beam.
PROCESS:
ADVANTAGES:

 Superior material properties.

 Complex parts.

 Reduced post-processing requirements.


LIMITATIONS:
 Limited materials.

 Large physical unit size.

 High power consumption.


APPLICATIONS:

 Build mold and die inserts.

 Producing titanium parts in racing industry.

 Fabricate titanium components for biological implants.

 Produce functionally gradient structures.


RECENT DEVELOPMENT:
Title : Additive manufacturing of alumina using laser engineered net
shaping: Effects of deposition variables.

Authors : Yuzhou Li, Yingbin Hu, Weilong Cong, Lin Zhi, Zhongning
Guo.

• Properties of alumina ceramic :

High hardness.
Strength.
High temperature resistance.
Good wear resistance.
Excellent corrosion resistance.
Low thermal conductivity and chemical inertness.
• Applications of alumina ceramic :

Automotive engine parts.

Aerospace components.

Electronic devices.

Medical containers and implants.

Machine tools.
Power material properties :

 Pure alumina with 99.99% purity.


 Particle size : 40-80 µm.

Experimental conditions :

Laser power : The value of power from laser generator


which can control the thermal value of laser.

Powder feeding rate : The value of sprayed powder


amount per minute.

Deposition head scanning speed : The scanning speed


of laser beam and powder stream.
Measurement procedure :

• Digital vernier caliper – To measure geometry properties.

• Weight ratio of deposited thin wall and sprayed powder over LENS
fabrication period – To calculate powder efficiency.

• Surface profilometer – To measure surface roughness.

• Difference of maximum and minimum height of each layer – To


measure flatness.
•Microhardness tester – To measure microhardness.
Results :

Effect of laser power on geometry of deposited part:

 Laser power changed from 175 to 250 W.


 Power feeding rate : 0.2 g/min.
 Deposition head scanning speed : 1000 mm/min.
 Length of deposited layer increases as laser power increases.
 After 200 W, the length was not increases rapidly.
 When power is 175-250 W, width increased slightly, for 200-250 W,
width change is very small around 1.5 mm.
Effect of laser power on surface condition :

• At laser power of 175 W, the energy input was not high enough to fully
melt the particles which causes high surface roughness.

• When the laser power increased from 175 W to 200 W, the surface
roughness decreased from 9.1 μm to 6.4 μm, indicating a significant
increase of fusibility of the absorbed particles.

Effect of laser power on powder efficiency:

• As the laser power increased from 175 W to 250 W, the powder


efficiency increased.

• Minimum value of powder efficiency - 22% at the laser power of 175


W and all the values of powder efficiency were below 30%.
Effect of laser power on microhardness:

• Laser power was increased from 200 to 250 W, the microhardness


increases from 1700 HV0.2 to 2300 HV0.2.

Effects of deposition head scanning speed:

On geometry of deposited parts:

• The deposition head scanning speed was changed from 500 mm/min to
1500 mm/min.
• Laser power 200 W
• Powder feeding rate 0.2 g/min.

• The length of the deposited layer slightly decreased from 16.2 mm to


15.7 mm.
Effects on surface conditions of deposited parts:

• With the deposition head scanning speed increasing from 500 mm/min
to 1250 mm/min, the surface roughness increased from 4.6 μm to 7.3
μm.

• Deposition head scanning speed from 1250 mm/min to 1500 mm/min,


the surface roughness slightly changed.
Effects on powder efficiency:

• With the deposition head scanning speed increasing from 500 mm/min
to 1500 mm/min, the powder efficiency decreased from 27% to 21%.
Effects on microhardness:
• The microhardness of the deposited layers was decreased from 2400
HV0.2 to 1450 HV0.2 with the increase of deposition head scanning
speed.
Effects of powder feeding rate:

On geometry of deposited parts:

 The powder feeding rate was changed from 0.1 g/min to 0.6 g/min.

 Laser power 200 W


 Deposition head scanning speed 1000 mm/min.

 The length and width of the deposited layer slightly changed.

 The height of deposited layer increased with the powder feeding rate
increasing from 0.1 g/min to 0.4 g/min.

But decreased with the powder feeding rate increasing from 0.4 g/min
to 0.6 g/min.
Effects on surface conditions of deposited parts:

o Powder feeding rate increasing from 0.1 g/min to 0.2 g/min, the
surface roughness decreased.

o The powder feeding rate was changed from 0.2 g/min to 0.4 g/min, the
surface roughness decreased slightly.

o The powder feeding rate from 0.2 g/min to 0.6 g/min, the value of
surface roughness (around 6.3 μm) remarkably decreased.

Effects on powder efficiency:

oAs the powder feeding rate increased from 0.1 g/min to 0.4 g/min, the
powder efficiency significantly increased from 17% to 27%.
Effects on microhardness:

 The microhardness decreased slightly from 2000 HV0.2 to 1700


HV0.2 with the powder feeding rate changing from 0.4 g/min to 0.6
g/min.
Conclusions:

 The increase of laser power led to the increase of length and width,
but slight changes of the height of the deposited layers. The surface
roughness, flatness, powder efficiency, and microhardness were
improved by increasing layer power.

 The increase of deposition head scanning speed results in the decrease


of length, width, height, powder efficiency, and microhardness of the
deposited layer.

 The deposition head scanning speed had negative impact on surface


roughness but positive impact on flatness.
 As the powder feeding rate increased, the length and width of the
deposited layer slightly changed, and the height of the deposited layer
firstly increased then decreased.

 When the powder feeding rate increased from 0.1 g/min to 0.4 g/min,
the powder efficiency increased and the microhardness decreased.

 However, when the powder feeding rate increased from 0.4 g/min to
0.6 g/ min, the powder efficiency decreased and the microhardness
slightly changed.
Title : Fe-Al thin walls manufactured by Laser Engineered Net Shaping.

Author : Krzysztof Karczewski, Magda Da browska, Michał Zie tala,


Marek Polanski

• Iron aluminum alloys based on the Fe3Al (DO3) and FeAl (B2)
ordered intermetallic phases can be used at higher temperatures.

• Better properties with a relatively lower density (5.4-6.7 g/cm3)

• Much lower raw material cost.


Materials and methods :

• The FeAl-based thin-walled samples were fabricated.

• The MPS allows control of the molten metal pool size, despite the
changing heat exchange conditions.

• Parameters :
Laser travelling velocity [mm/s],
Powder flow rate [g/min] and
Defined layer thickness [mm].

• Nitrogen-gas atomized spherical Fe-16Al (wt%) alloyed powder with a


particle size of 40-150 mm was used.
Results and discussion :

Powder characterization :

Stereological analysis.

Porosity of 0.3% inside the powder particles.

Still result in some gas porosity in the final product.

Chemical analysis (EDS) :

Elemental ratio required to form the Fe3Al phase.

Phase identification (XRD pattern)

The powders did not possess the DO3 crystallographic structure, but that
they had the B2 structure.
Sample manufacturing :

• To build thin-walled (0.5-5 mm) components by changing the number


of laser beam tracks parallel to each other in a single layer.

Deposition velocity 9 mm/s,


Powder mass flow 12 g/min
Layer thickness 0.25 mm.

• Sample with an assumed 0.5 mm wall thickness was obtained.

• Two thin-walled box-like samples (80*10*30 mm) (L*W*H), were


manufactured. For thicker walled samples (2-5 mm).

Microstructural and metallurgical quality analysis of the Samples :

• Based on macro-images - The porosity was determined to be 0.3%,


0.1%, 0.1% and 0.9% for wall thickness of 0.5, 1, 2 and 5 mm.
• Wall thickness of 0.5 mm, the elongated coarse grains had an average
size of approximately 200 mm.

• The grain size was 200-300 mm for walls of 1mm For 2 and 5 mm wall
thicknesses.

• The grains grew through few subsequent layers and had an average size
of 200-800 mm.

XRD phase analysis :

• LENS-fabricated samples possess a B2-type structure, except for the


0.5 mm wall sample, which seems to have the DO3-type structure.
• Cause - high cooling rates during the deposition of the thicker walled
samples.
• For the lower cooling rates observed in the case of the 0.5 mm thick
sample, the DO3 structure was formed.

Mechanical properties analysis :


Microhardness measurements :
•The 0.5 and 1mm samples have similar microhardness values (337 ± 13
HV and 333 ± 15 HV, respectively).
•Thereafter, microhardness increases with the thickness of the samples,
reaching a similar value of 371 ± 18 HV and 381 ± 17 HV for 2 and 5
mm wall thickness respectively.
Tension test :
Conclusions :
Fabrication of thin-walled elements with a minimum wall thickness
of 0.5 mm from the Fe-16Al (wt%) alloy powder is possible.

The proper selection of process parameters allows production of Fe-


16Al samples with wall thicknesses up to 5 mm by changing the
number of laser beam tracks for a single layer.

 The maximum cooling rate increases with increasing wall thickness


of the parts.
REFERENCES :
 [1] Yuzhou Lia,b, Yingbin Hub, Weilong Congb,⁎, Lin Zhia,
Zhongning Guoa, Additive manufacturing of alumina using laser
engineered net shaping: Effects of deposition variables, Ceramics
International.

 [2] Krzysztof Karczewski, Magda Da˛browska, Michał Zie˛ tala,


Marek Polanski, Fe-Al thin walls manufactured by Laser Engineered
Net Shaping, Journal of Alloys and Compounds, vol. 696, 2017, pp.
1105-1112.

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