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Open AccessArticle

Effect of Process Parameters on the Generated Surface Roughness of Down-Facing Surfaces in Selective Laser Melting

1
Institute for Automation and Applied Informatics, Karlsruhe Institute of Technology, 76344 Eggenstein-Leopoldshafen, Germany
2
Faculty of Engineering, Port Said University, Port Fuad 42526, Egypt
3
Direct Metal Printing Engineering, 3D Systems, 3001 Leuven, Belgium
4
Karlsruhe Nano Micro Facility, Hermann-von-Helmholtz-Platz 1, 76344 Eggenstein-Leopoldshafen, Germany
*
Author to whom correspondence should be addressed.
Appl. Sci. 2019, 9(6), 1256; https://doi.org/10.3390/app9061256
Received: 26 February 2019 / Revised: 18 March 2019 / Accepted: 20 March 2019 / Published: 26 March 2019
(This article belongs to the Special Issue Micro/Nano Manufacturing)
Additive manufacturing provides a number of benefits in terms of infinite freedom to design complex parts and reduced lead-times while globally reducing the size of supply chains as it brings all production processes under one roof. However, additive manufacturing (AM) lags far behind conventional manufacturing in terms of surface quality. This proves a hindrance for many companies considering investment in AM. The aim of this work is to investigate the effect of varying process parameters on the resultant roughness of the down-facing surfaces in selective laser melting (SLM). A systematic experimental study was carried out and the effects of the interaction of the different parameters and their effect on the surface roughness (Sa) were analyzed. It was found that the interaction and interdependency between parameters were of greatest significance to the obtainable surface roughness, though their effects vary greatly depending on the applied levels. This behavior was mainly attributed to the difference in energy absorbed by the powder. Predictive process models for optimization of process parameters for minimizing the obtained Sa in 45° and 35° down-facing surface, individually, were achieved with average error percentages of 5% and 6.3%, respectively, however further investigation is still warranted. View Full-Text
Keywords: additive manufacturing; selective laser melting; surface roughness; design of experiments; Ti6Al4V additive manufacturing; selective laser melting; surface roughness; design of experiments; Ti6Al4V
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MDPI and ACS Style

Charles, A.; Elkaseer, A.; Thijs, L.; Hagenmeyer, V.; Scholz, S. Effect of Process Parameters on the Generated Surface Roughness of Down-Facing Surfaces in Selective Laser Melting. Appl. Sci. 2019, 9, 1256. https://doi.org/10.3390/app9061256

AMA Style

Charles A, Elkaseer A, Thijs L, Hagenmeyer V, Scholz S. Effect of Process Parameters on the Generated Surface Roughness of Down-Facing Surfaces in Selective Laser Melting. Applied Sciences. 2019; 9(6):1256. https://doi.org/10.3390/app9061256

Chicago/Turabian Style

Charles, Amal; Elkaseer, Ahmed; Thijs, Lore; Hagenmeyer, Veit; Scholz, Steffen. 2019. "Effect of Process Parameters on the Generated Surface Roughness of Down-Facing Surfaces in Selective Laser Melting" Appl. Sci. 9, no. 6: 1256. https://doi.org/10.3390/app9061256

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