Unlike conventional materials removal methods, additive manufacturing (AM) is based on a novel materials incremental manufacturing philosophy. Additive manufacturing implies layer by layer shaping and consolidation of powder feedstock to arbitrary configurations, normally using a computer controlled laser. The current development focus of AM is to produce complex shaped functional metallic components, including metals, alloys and metal matrix composites (MMCs), to meet demanding requirements from aerospace, defence, automotive and biomedical industries. Laser sintering (LS), laser melting (LM) and laser metal deposition (LMD) are presently regarded as the three most versatile AM processes. Laser based AM processes generally have a complex non-equilibrium physical and chemical metallurgical nature, which is material and process dependent. The influence of material characteristics and processing conditions on metallurgical mechanisms and resultant microstructural and mechanical properties of AM proc...

Laser additive manufacturing of metallic components: materials, processes and mechanisms

Selective Laser Melting (SLM) is a particular rapid prototyping, 3D printing, or Additive Manufacturing (AM) technique designed to use high power-density laser to melt and fuse metallic powders. A component is built by selectively melting and fusing powders within and between layers. The SLM technique is also commonly known as direct selective laser sintering, LaserCusing, and direct metal laser sintering, and this technique has been proven to produce near net-shape parts up to 99.9% relative density. This enables the process to build near full density functional parts and has viable economic benefits. Recent developments of fibre optics and high-power laser have also enabled SLM to process different metallic materials, such as copper, aluminium, and tungsten. Similarly, this has also opened up research opportunities in SLM of ceramic and composite materials. The review presents the SLM process and some of the common physical phenomena associated with this AM technology. It then focuses on the following a...

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Review of selective laser melting : materials and applications

Topological design and additive manufacturing of porous metals for bone scaffolds and orthopaedic implants: A review.

Consolidation phenomena in laser and powder-bed based layered manufacturing

A review on selective laser sintering/melting (SLS/SLM) of aluminium alloy powders: Processing, microstructure, and properties

Sintering of commercially pure titanium powder with a Nd:YAG laser source

A thermal model of selective laser sintering (SLS) has been developed. The model allows for the non-linear behavior of thermal conductivity and of specific heat due to temperature changes and phase transformations. The temperature evolution and the formation of the sintered part are simulated by a 3D finite element analysis based on continuous media theory. It is shown that the effect of sintering has a strong influence on thermal evolution through changing the thermal properties of the material. The results of the model were experimentally tested and confirmed by temperature measurements.

3D FE simulation for temperature evolution in the selective laser sintering process

A thermal model of the interaction of pulsed near-infrared laser radiation from a Nd:YAG laser was made, taking the measured powder properties such as reflectance, optical penetration depth and thermal conductivity into account. It allows an estimation of the evolution of two different temperatures: the average temperature of the powder (taken over the grains in a volume given by the laser beam diameter and the optical penetration depth) and the temperature distinction within a single grain. It showed that in pulsed mode consolidation can be achieved at much lower average power as the surface of the powder particles are molten but their cores remain at nearly room temperature. This leads to a much lower average temperature and therefore a dramatic decrease in residual thermal stresses in the finished piece. The results of the model were experimentally tested and confirmed.

A model for the interaction of near-infrared laser pulses with metal powders in selective laser sintering

Numerical calculations performed with a model for the interaction of near infrared laser pulses with metallic powders are compared with the temperature measurement obtained with an infrared camera. Furthermore, a comparison of the temperature measurements between continuous wave sintering and pulsed sintering is presented and the predicted difference of skin and average temperature upon pulsed interaction is verified.

P. Fischer

Papers

Sintering of commercially pure titanium powder with a Nd:YAG laser source

3D FE simulation for temperature evolution in the selective laser sintering process

A model for the interaction of near-infrared laser pulses with metal powders in selective laser sintering

Temperature measurements during selective laser sintering of titanium powder

Pulsed laser sintering of metallic powders