Laser Powder Bed Fusion Tool Repair: Statistical Analysis of 1.2343/H11 Tool Steel Process Parameters and Microstructural Analysis of the Repair Interface
Abstract
:1. Introduction
2. Materials and Methods
2.1. Materials
2.2. LPBF Manufacturing
- 120 cubes (10 × 10 × 10 mm3) for relative density and microstructure analysis.
- 6 B4 × 20 tensile samples. Three of those samples were tested in as-built condition, the remaining three samples were sand blasted prior to tensile testing.
- 12 cylinders ( for tensile testing, which are subsequently machined into B4 × 20 tensile samples.
- 18 cubes with circular channels (see Figure 2). The edge length of the cube is 16 mm, the channel diameter of the surface-centered channel structures is 6 mm. The sample geometry was chosen according to the results of Thomas [8]; a wall thickness (t) of 5 mm reduces the risk of sample damage when removing the test geometries [8]. Furthermore, a channel diameter of 6 mm reduces the probability that the powder within the channel structure will be sintered by the energy input.
2.3. Relative Density
2.4. Microstructure
2.5. Tensile Testing
2.6. Support Free Channel
2.7. Surface Roughness
2.8. Tool Repair
3. Results
3.1. Relative Density and Microstructure
3.2. Surface Roughness
3.3. Tensile Properties
3.4. Tool Repair
4. Discussion
- Liquid volume fraction between 0.1–0.01
- Liquid volume fraction between 0.6–0.1
- A high relative density is necessary to avoid defects. Too high an energy density leads to keyholing and if the energy density is too low, lack of fusion is found.
- For improved channel diameter compliance, it was found that a minimum energy density leads to better results. This will cause a trade off when considering the relative density for the remaining volume of the component.
- When considering surface roughness, the combination of scan speed and hatch distance played the largest role. Here, the possibility of adjusting contour parameters with this parameter combination would avoid adjusting the energy density for the entire component.
5. Conclusions and Outlook
- An energy density of 69.93 J/mm3 and no preheating was used.
- No pores or cracks could be found.
- The tensile properties agree with those reported in literature.
- Preheating only showed a limited effect on reducing crack density.
- The hardness is not homogenously spread.
- CT scans of the repaired tool should also be considered in further studies to identify defects within the volume of the insert.
- Lower energy input is recommended for improved geometric compliance of channel structures. Higher energy densities lead to sagging of the surface layers and reduce dimensional stability.
- Hatch distance, scan speed, and laser power should be adjusted in descending order to optimize the minimum channel diameter. It is recommended to use a small hatch distance and fast scan speed combined with a high laser power. The energy density range of 50–150 J/mm3 should be considered to simultaneously achieve high relative densities.
- The interaction of scan speed and hatch distance has a significant effect on geometric compliance and surface roughness and should be further investigated in further studies.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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C | Fe | Si | V | Cr | Mn | Mo | |
---|---|---|---|---|---|---|---|
wt.% | 0.37 | Rest | 1.6 | 0.7 | 7.39 | 0.05 | 1.4 |
Energy Density | 34.19 J/mm3 | 58.28 J/mm3 | 94.7 J/mm3 |
---|---|---|---|
Ra Channel Ceiling | 48 ± 6 µm | 70 ± 1 µm | 96 ± 10 µm |
Ra Channel Floors | 54 ± 6 µm | 4 ± 1 µm | 106 ± 10 µm |
Factor(s) | Value Effect/Interaction |
---|---|
ScanSpeed × Hatch Distance | 2.71 |
Laser Power × Scan Speed × Hatch Distance | 1.25 |
Laser Power × Hatch Distance | 0.33 |
Laser Power | 0.10 |
Hatch Distance | −0.08 |
Scan Speed | −0.07 |
Laser Power × Scan Speed | 0.04 |
Factor(s) | Value Effect/Interaction |
---|---|
Hatch Distance | 527.12 |
Scan Speed | 403.90 |
Laser Power | −370.08 |
Laser Power × Scan Speed × Hatch Distance | −312.93 |
Scan speed × Hatch Distance | −196.39 |
Laser Power × Hatch Distance | 86.33 |
Laser Power × Scan Speed | 56.78 |
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Megahed, S.; Koch, R.; Schleifenbaum, J.H. Laser Powder Bed Fusion Tool Repair: Statistical Analysis of 1.2343/H11 Tool Steel Process Parameters and Microstructural Analysis of the Repair Interface. J. Manuf. Mater. Process. 2022, 6, 139. https://doi.org/10.3390/jmmp6060139
Megahed S, Koch R, Schleifenbaum JH. Laser Powder Bed Fusion Tool Repair: Statistical Analysis of 1.2343/H11 Tool Steel Process Parameters and Microstructural Analysis of the Repair Interface. Journal of Manufacturing and Materials Processing. 2022; 6(6):139. https://doi.org/10.3390/jmmp6060139
Chicago/Turabian StyleMegahed, Sandra, Raphael Koch, and Johannes Henrich Schleifenbaum. 2022. "Laser Powder Bed Fusion Tool Repair: Statistical Analysis of 1.2343/H11 Tool Steel Process Parameters and Microstructural Analysis of the Repair Interface" Journal of Manufacturing and Materials Processing 6, no. 6: 139. https://doi.org/10.3390/jmmp6060139