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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.

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


Authors

Nesma T. Aboulkhair

Ge Zhao

RICHARD HAGUE RICHARD.HAGUE@NOTTINGHAM.AC.UK
Professor of Additive Manufacturing

Andrew R. Kennedy

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

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



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 Mar 29, 2024
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.

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