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Targeted rework of powder bed fusion additive manufacturing

Dryburgh, Paul; Patel, Rikesh; Catchpole-Smith, Sam; Hirsch, Matthias; Parry, Luke; Smith, Richard J.; Clark, Matt; Ashcroft, Ian A.; Clare, Adam T

Authors

Paul Dryburgh paul.dryburgh@nottingham.ac.uk

Sam Catchpole-Smith Sam.Catchpole-Smith@nottingham.ac.uk

Matthias Hirsch

Luke Parry ezalp6@exmail.nottingham.ac.uk

RICHARD SMITH richard.j.smith@nottingham.ac.uk
Assistant Professor in Optical and Electronic Engineering

MATT CLARK matt.clark@nottingham.ac.uk
Professor of Applied Optics

IAN ASHCROFT Ian.Ashcroft@nottingham.ac.uk
Professorof Mechanics of Solids

ADAM CLARE adam.clare@nottingham.ac.uk
Professor of Manufacturing Engineering



Abstract

There is a clear industrial pull to fabricate high value components using premium high temperature aerospace materials by additive manufacturing. Inconveniently, the same materials’ properties which allow them to perform well in service render them difficult to process via powder bed fusion. Current build systems are characterised by high defect rates and erratic microstructure, leading to components with inferior mechanical properties. Given the high specific costs in powder bed fusion manufacture there is a real and apparent need to minimise component scrappage due to these defects. Here a method is proposed to make good the defects that will inevitably be produced in current class laser processing of metallic powders. This study investigates the use of spatially resolved acoustic spectroscopy (SRAS) scan data to inform repair strategies within a commercial selective laser melting machine. Using the common aerospace nickel superalloys, Inconel 718 and CM247-LC, localised remelting was shown to consistently reduce the depth of defect. A 50 % reduction in defect depth was observed for both materials using different rework strategies. No appreciable variation was seen with the single-shot strategy, due inaccurate realignment.

Start Date Jun 25, 2018
Publication Date Jun 25, 2018
Pages #18/030
Book Title Proceedings of LPM2018 - the 19th International Symposium on Laser Precision Microfabrication
Chapter Number 30
ISBN n/a
APA6 Citation Dryburgh, P., Patel, R., Catchpole-Smith, S., Hirsch, M., Parry, L., Smith, R. J., …Clare, A. T. (2018). Targeted rework of powder bed fusion additive manufacturing. In Proceedings of LPM2018 - the 19th International Symposium on Laser Precision Microfabrication. , (#18/030)
Publisher URL http://www.jlps.gr.jp/en/proc/lpm/18/

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