The Dimensional Accuracy of Thin-Walled Parts Manufactured by Laser-Powder Bed Fusion Process

Tomas, Josef; Hitzler, Leonhard; Köller, Marco; von Kobylinski, Jonas; Sedlmajer, Michael; Werner, Ewald; Merkel, Markus

doi:10.3390/jmmp4030091

Open AccessArticle

The Dimensional Accuracy of Thin-Walled Parts Manufactured by Laser-Powder Bed Fusion Process

by

Josef Tomas

^1,*

,

Leonhard Hitzler

^2,*

,

Marco Köller

¹

,

Jonas von Kobylinski

²

,

Michael Sedlmajer

¹

,

Ewald Werner

²

and

Markus Merkel

¹

Institute for Virtual Product Develeopment, Aalen University of Applied Science, Beethovenstr. 1, 73430 Aalen, Germany

²

Institute of Materials Science and Mechanics of Materials, Technical University of Munich, Boltzmanstr. 15, 85748 Garching, Germany

^*

Authors to whom correspondence should be addressed.

J. Manuf. Mater. Process. 2020, 4(3), 91; https://doi.org/10.3390/jmmp4030091

Submission received: 6 August 2020 / Revised: 3 September 2020 / Accepted: 3 September 2020 / Published: 11 September 2020

(This article belongs to the Special Issue Powder Metallurgy and Additive Manufacturing/3D Printing of Materials)

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Abstract

Laser-Powder Bed Fusion brings new possibilities for the design of parts, e.g., cutter shafts with integrated cooling channels close to the contour. However, there are new challenges to dimensional accuracy in the production of thin-walled components, e.g., heat exchangers. High degrees of dimensional accuracy are necessary for the production of functional components. The aim is to already achieve these during the process, to reduce post-processing costs and time. In this work, thin-walled ring specimens of H13 tool steel are produced and used for the analysis of dimensional accuracy and residual stresses. Two different scanning strategies were evaluated. One is a stripe scan strategy, which was automatically generated and provided by the machine manufacturer, and a (manually designed) sectional scan strategy. The ring segment strategy is designed by manually segmenting the geometry, which results in a longer preparation time. The samples were printed in different diameters and analyzed with respect to the degree of accuracy and residual stresses. The dimensional accuracy of ring specimens could be improved by up to 81% with the introduced sectional strategy compared to the standard approach.

Keywords: H13; 1.2344; tool steel; scan strategy; metal printing

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MDPI and ACS Style

Tomas, J.; Hitzler, L.; Köller, M.; von Kobylinski, J.; Sedlmajer, M.; Werner, E.; Merkel, M. The Dimensional Accuracy of Thin-Walled Parts Manufactured by Laser-Powder Bed Fusion Process. J. Manuf. Mater. Process. 2020, 4, 91. https://doi.org/10.3390/jmmp4030091

AMA Style

Tomas J, Hitzler L, Köller M, von Kobylinski J, Sedlmajer M, Werner E, Merkel M. The Dimensional Accuracy of Thin-Walled Parts Manufactured by Laser-Powder Bed Fusion Process. Journal of Manufacturing and Materials Processing. 2020; 4(3):91. https://doi.org/10.3390/jmmp4030091

Chicago/Turabian Style

Tomas, Josef, Leonhard Hitzler, Marco Köller, Jonas von Kobylinski, Michael Sedlmajer, Ewald Werner, and Markus Merkel. 2020. "The Dimensional Accuracy of Thin-Walled Parts Manufactured by Laser-Powder Bed Fusion Process" Journal of Manufacturing and Materials Processing 4, no. 3: 91. https://doi.org/10.3390/jmmp4030091

APA Style

Tomas, J., Hitzler, L., Köller, M., von Kobylinski, J., Sedlmajer, M., Werner, E., & Merkel, M. (2020). The Dimensional Accuracy of Thin-Walled Parts Manufactured by Laser-Powder Bed Fusion Process. Journal of Manufacturing and Materials Processing, 4(3), 91. https://doi.org/10.3390/jmmp4030091

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The Dimensional Accuracy of Thin-Walled Parts Manufactured by Laser-Powder Bed Fusion Process

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