Electrical Smoothing of the Powder Bed Surface in Laser-Based Powder Bed Fusion of Metals

Hofmann, Andreas; Grotz, Tim; Köstler, Nico; Mahr, Alexander; Döpper, Frank

doi:10.3390/jmmp8030112

Open AccessArticle

Electrical Smoothing of the Powder Bed Surface in Laser-Based Powder Bed Fusion of Metals

by

Andreas Hofmann

^1,2,*

,

Tim Grotz

²

,

Nico Köstler

²,

Alexander Mahr

^1,2 and

Frank Döpper

^1,2

¹

Fraunhofer Institute for Manufacturing Engineering and Automation IPA, Universitaetsstraße 9, 95447 Bayreuth, Germany

²

Chair of Manufacturing and Remanufacturing Technology, University of Bayreuth, Universitaetsstraße 30, 95447 Bayreuth, Germany

^*

Author to whom correspondence should be addressed.

J. Manuf. Mater. Process. 2024, 8(3), 112; https://doi.org/10.3390/jmmp8030112

Submission received: 1 May 2024 / Revised: 15 May 2024 / Accepted: 24 May 2024 / Published: 28 May 2024

(This article belongs to the Special Issue Design, Processes and Materials for Additive Manufacturing)

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Abstract

Achieving a homogeneous and uniform powder bed surface as well as a defined, uniform layer thickness is crucial for achieving reproducible component properties that meet requirements when powder bed fusion of metals with a laser beam. The existing recoating processes cause wear of the recoater blade due to protruded, melted obstacles, which affects the powder bed surface quality locally. Impairments to the powder bed surface quality have a negative effect on the resulting component properties such as surface quality and relative density. This can lead either to scrapped components or to additional work steps such as surface reworking. In this work, an electric smoother is presented with which a wear-free and contactless smoothing of the powder bed can be realized. The achievable powder bed surface quality was analyzed using optical profilometry. It was found that the electric smoother can compensate for impairments in the powder bed surface and achieve a reproducible surface quality of the powder bed regardless of the initial extent of the impairments. Consequently, the electric smoother offers a promising opportunity to reduce the scrap rate in PBF-LB/M and to increase component quality.

Keywords: additive manufacturing; powder bed fusion; powder bed surface quality; powder bed leveling; electrical smoothing

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MDPI and ACS Style

Hofmann, A.; Grotz, T.; Köstler, N.; Mahr, A.; Döpper, F. Electrical Smoothing of the Powder Bed Surface in Laser-Based Powder Bed Fusion of Metals. J. Manuf. Mater. Process. 2024, 8, 112. https://doi.org/10.3390/jmmp8030112

AMA Style

Hofmann A, Grotz T, Köstler N, Mahr A, Döpper F. Electrical Smoothing of the Powder Bed Surface in Laser-Based Powder Bed Fusion of Metals. Journal of Manufacturing and Materials Processing. 2024; 8(3):112. https://doi.org/10.3390/jmmp8030112

Chicago/Turabian Style

Hofmann, Andreas, Tim Grotz, Nico Köstler, Alexander Mahr, and Frank Döpper. 2024. "Electrical Smoothing of the Powder Bed Surface in Laser-Based Powder Bed Fusion of Metals" Journal of Manufacturing and Materials Processing 8, no. 3: 112. https://doi.org/10.3390/jmmp8030112

APA Style

Hofmann, A., Grotz, T., Köstler, N., Mahr, A., & Döpper, F. (2024). Electrical Smoothing of the Powder Bed Surface in Laser-Based Powder Bed Fusion of Metals. Journal of Manufacturing and Materials Processing, 8(3), 112. https://doi.org/10.3390/jmmp8030112

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Electrical Smoothing of the Powder Bed Surface in Laser-Based Powder Bed Fusion of Metals

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