Generation of graded porous structures by control of process parameters in the selective laser melting of a fixed ratio salt-metal feedstock

Aboulkhair, Nesma T.; Zhao, Ge; Hague, Richard J.M.; Kennedy, Andrew R.; Ashcroft, Ian A.; Clare, Adam T.

Abstract

The demonstration of salt dissolution incorporated within laser powder-bed fusion fabrication processes has allowed the creation of complex porous structures without the need for sophisticated design algorithms. This serves to simplify the process, for porous structure creation in powder-bed fabrication techniques, creating a new opportunity for the realisation of optimised structures. A new methodology is presented here in which modulation of the energy density while using a single feedstock material enables three-dimensional control of porosity, ranging from 20% to 49%. Through structured experimentation, the response of the material to varying the process parameters in selective laser melting is evaluated and nested structures of distinct densities and morphologies are created. Correlation of the process parameters with modulus and ultimate compressive stress are established. A simple-assembly algorithm was used to generate complex parts consisting of locally assigned porosities having characteristic properties.

Citation

Aboulkhair, N. T., Zhao, G., Hague, R. J., Kennedy, A. R., Ashcroft, I. A., & Clare, A. T. (2020). Generation of graded porous structures by control of process parameters in the selective laser melting of a fixed ratio salt-metal feedstock. Journal of Manufacturing Processes, 55, 249-253. https://doi.org/10.1016/j.jmapro.2020.04.039

• Journal Article Type: Article
• Acceptance Date: Apr 10, 2020
• Online Publication Date: Apr 22, 2020
• Publication Date: Apr 22, 2020
• Deposit Date: Apr 17, 2020
• Publicly Available Date: Apr 23, 2022
• Journal: Journal of Manufacturing Processes
• Print ISSN: 1526-6125
• Publisher: Elsevier
• Peer Reviewed: Peer Reviewed
• Volume: 55
• Pages: 249-253
• DOI: https://doi.org/10.1016/j.jmapro.2020.04.039
• Keywords: Management Science and Operations Research; Strategy and Management; Industrial and Manufacturing Engineering
• Public URL: https://nottingham-repository.worktribe.com/output/4300315
• Publisher URL: https://www.sciencedirect.com/science/article/abs/pii/S1526612520302632
• Additional Information: This article is maintained by: Elsevier; Article Title: Generation of graded porous structures by control of process parameters in the selective laser melting of a fixed ratio salt-metal feedstock; Journal Title: Journal of Manufacturing Processes; CrossRef DOI link to publisher maintained version: https://doi.org/10.1016/j.jmapro.2020.04.039; Content Type: article; Copyright: © 2020 The Society of Manufacturing Engineers. Published by Elsevier Ltd. All rights reserved.