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10.3390/ma16247626
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Article

Process Parameter Optimization for Laser Powder Bed Fusion of Fe-Si Alloy Considering Surface Morphology and Track Width of Single Scan Track

by
Ho Sung Jang
1,2,
Su Heon Kim
1,2,
Geon-Woo Park
3,4,
Jong Bae Jeon
5,*,
Donghwi Kim
6,
Dohyung Kim
3,
Wang Ryeol Kim
3,
Yoon Suk Choi
2,* and
Sunmi Shin
1,*
1
Advanced Forming Process R&D Group, Korea Institute of Industrial Technology, Ulsan 44776, Republic of Korea
2
School of Materials Science and Engineering, Pusan National University, Busan 46241, Republic of Korea
3
Dongnam Regional Division, Korea Institute of Industrial Technology, Yangsan 50623, Republic of Korea
4
Department of Materials Science and Engineering, Ulsan National Institute of Science and Technology, Ulsan 44919, Republic of Korea
5
Department of Materials Science and Engineering, Dong-A University, Busan 49315, Republic of Korea
6
Computational Materials Research Team, Hyundai Motor Group, Uiwang 16082, Republic of Korea
*
Authors to whom correspondence should be addressed.
Materials 2023, 16(24), 7626; https://doi.org/10.3390/ma16247626
Submission received: 31 October 2023 / Revised: 30 November 2023 / Accepted: 8 December 2023 / Published: 13 December 2023
(This article belongs to the Section Metals and Alloys)
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Abstract

A laser power bed fusion (L-PBF) manufacturing process was optimized by analyzing the surface morphology and track width w of single scan tracks (SSTs) on Fe-3.4wt.%Si. An SST was evaluated under process conditions of laser power P, scan speed V, and energy density E = P/V. The SST surface shape was mainly affected by E; desirable thin and regular tracks were obtained at E = 0.3 and 0.4 J/mm. An L-PBF process window was proposed considering the optimal w of SST, and the appropriate range of E for the alloy was identified to be 0.24 J/mm to 0.49 J/mm. w showed a strong relationship with E and V, and an analytic model was suggested. To verify the process window derived from the appropriate w of SST, cubic samples were manufactured with the estimated optimal process conditions. Most samples produced had a high density with a porosity of <1%, and the process window derived from SST w data had high reliability. This study presents a comprehensive approach to enhancing additive manufacturing for Fe-3.4Si alloy, offering valuable insights for achieving high-quality samples without the need for time-intensive procedures.
Keywords: selective laser melting; silicon steel; additive manufacturing; process optimization; single-track scanning selective laser melting; silicon steel; additive manufacturing; process optimization; single-track scanning

Share and Cite

MDPI and ACS Style

Jang, H.S.; Kim, S.H.; Park, G.-W.; Jeon, J.B.; Kim, D.; Kim, D.; Kim, W.R.; Choi, Y.S.; Shin, S. Process Parameter Optimization for Laser Powder Bed Fusion of Fe-Si Alloy Considering Surface Morphology and Track Width of Single Scan Track. Materials 2023, 16, 7626. https://doi.org/10.3390/ma16247626

AMA Style

Jang HS, Kim SH, Park G-W, Jeon JB, Kim D, Kim D, Kim WR, Choi YS, Shin S. Process Parameter Optimization for Laser Powder Bed Fusion of Fe-Si Alloy Considering Surface Morphology and Track Width of Single Scan Track. Materials. 2023; 16(24):7626. https://doi.org/10.3390/ma16247626

Chicago/Turabian Style

Jang, Ho Sung, Su Heon Kim, Geon-Woo Park, Jong Bae Jeon, Donghwi Kim, Dohyung Kim, Wang Ryeol Kim, Yoon Suk Choi, and Sunmi Shin. 2023. "Process Parameter Optimization for Laser Powder Bed Fusion of Fe-Si Alloy Considering Surface Morphology and Track Width of Single Scan Track" Materials 16, no. 24: 7626. https://doi.org/10.3390/ma16247626

APA Style

Jang, H. S., Kim, S. H., Park, G.-W., Jeon, J. B., Kim, D., Kim, D., Kim, W. R., Choi, Y. S., & Shin, S. (2023). Process Parameter Optimization for Laser Powder Bed Fusion of Fe-Si Alloy Considering Surface Morphology and Track Width of Single Scan Track. Materials, 16(24), 7626. https://doi.org/10.3390/ma16247626

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