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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

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Authors

Paul Dryburgh

Sam Catchpole-Smith

Matthias Hirsch

Luke Parry

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

IAN ASHCROFT IAN.ASHCROFT@NOTTINGHAM.AC.UK
Professor of 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.

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)

Conference Name 19th International Symposium on Laser Precision Microfabrication
Start Date Jun 25, 2018
End Date Jun 27, 2018
Acceptance Date Jul 17, 2018
Publication Date Jun 25, 2018
Deposit Date Oct 25, 2018
Publicly Available Date Oct 26, 2018
Pages #18/030
Book Title Proceedings of LPM2018 - the 19th International Symposium on Laser Precision Microfabrication
Chapter Number 30
ISBN n/a
Public URL https://nottingham-repository.worktribe.com/output/1190715
Publisher URL http://www.jlps.gr.jp/en/proc/lpm/18/
Contract Date Oct 25, 2018

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