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Ways to increase the productivity of L-PBF processes

Kasprowicz Marcin, Pawlak Andrzej, Jurkowski Paweł, Kurzynowski Tomasz

Archives of Civil and Mechanical Engineering

2023

Vol. 23, no. 3

art. no. e211, 2023

One of the main limitations of additive manufacturing (AM) technologies consists in the relatively low build rate. Low productivity discourages companies from investing in AM machines, thus limiting the market of additive technologies. Machine manufacturers have introduced new solutions to their designs to increase the build rate, some of them are described in this paper. However, design improvements are not the only method to accelerate the process. The paper specifies factors that influence the build rate in the laser powder bed fusion process and provides an analytical assessment and comparison of the significance of how they affect its productivity. The influence that a change in selected parameters has on the process and the influence of multi-laser systems on its productivity are analysed in terms of the melted material quality. The processes from which the data for analysis were obtained were carried out on an SLM 280 machine with single- and dual-laser versions as well as on an SLM 500 with four lasers. Two types of samples, solid and thin-walled, both of the same volume, were tested. The data under analysis were the process times for both geometries, manufactured with different sets of parameters from the adopted range. Processing times were analysed to determine the main effects and interaction effects for extreme values of a given parameter. The height of the melted powder layer had the greatest influence on the build rate, which turned out to be greater even than the application of a two-laser system.

The potential of SLM technology for processing magnesium alloys in aerospace industry

Kurzynowski T., Pawlak A., Smolina I.

Archives of Civil and Mechanical Engineering

2020

Vol. 20, no. 1

327--339

Selective Laser Melting (SLM) of magnesium alloys is the technology undergoing dynamic development in many research centres. The results are promising and make it possible to manufacture defect-free material with better properties than those offered by the manufacturing technologies used to date. This review aims to evaluate present state as well as main challenges of using Laser Powder Bed Fusion (L-PBF) for processing magnesium alloys as an alternative way to conventional technolo-gies to manufacture parts in the aerospace industry. This literature review is the first one to outline information concerning the potential to use magnesium alloys in the aerospace industry as well as to summarise the results of magnesium alloy pro-cessing using AM technologies, in particular L-PBF. The available literature was reviewed to gather information about: the use of magnesium alloys in the aerospace industry-the benefits and limitations of using magnesium and its alloys, examples of applications using new processing methods to manufacture aerospace parts, the benefits and potential of using L-PBF to process metallic materials, examples of the use of L-PBF to manufacture aerospace parts, and state-of-the-art research into L-PBF processing of magnesium and magnesium alloys.