On the measurement of effective powder layer thickness in laser powder-bed fusion additive manufacturing of metals

Yahya Mahmoodkhani; Usman Ali; Shahriar Imani Shahabad; Adhitan Rani Kasinathan; Reza Esmaeilizadeh; Ali Keshavarzkermani; Ehsan Marzbanrad; Ehsan Toyserkani

doi:10.1007/s40964-018-0064-0

On the measurement of effective powder layer thickness in laser powder-bed fusion additive manufacturing of metals

Yahya Mahmoodkhani, Usman Ali, Shahriar Imani Shahabad, Adhitan Rani Kasinathan, Reza Esmaeilizadeh, Ali Keshavarzkermani, Ehsan Marzbanrad, Ehsan Toyserkani^*

^*Corresponding author for this work

Research output: Contribution to journal › Article › peer-review

63 Scopus citations

Abstract

In laser powder-bed fusion (LPBF), the actual thickness of powder particles that spread on solidified zones, so-called effective layer thickness (ELT), is higher than the nominal layer thickness. The source cause of this discrepancy is the fact that powder particles substantially shrink after selective melting, followed by solidification. ELT, as an unknown parameter, depends on process parameters and material properties. In this study, an effective method to measure ELT is proposed and applied to 17-4 PH stainless steel for a nominal build layer thickness of 20 µm. The measured ELT was larger than 100 µm, which is far beyond the values reported in the literature. Results obtained from the current study show the effect of applying the ELT rather than the nominal build layer thickness in numerical modeling studies as well as understanding the governing physics in the LPBF process.

Original language	English
Pages (from-to)	109-116
Number of pages	8
Journal	Progress in Additive Manufacturing
Volume	4
Issue number	2
DOIs	https://doi.org/10.1007/s40964-018-0064-0
State	Published - 1 Jun 2019
Externally published	Yes

Bibliographical note

Publisher Copyright:
© 2018, Springer Nature Switzerland AG.

Keywords

Additive manufacturing
Effective layer thickness
Laser–powder bed fusion

ASJC Scopus subject areas

Industrial and Manufacturing Engineering

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

Access to Document

10.1007/s40964-018-0064-0

Cite this

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title = "On the measurement of effective powder layer thickness in laser powder-bed fusion additive manufacturing of metals",

abstract = "In laser powder-bed fusion (LPBF), the actual thickness of powder particles that spread on solidified zones, so-called effective layer thickness (ELT), is higher than the nominal layer thickness. The source cause of this discrepancy is the fact that powder particles substantially shrink after selective melting, followed by solidification. ELT, as an unknown parameter, depends on process parameters and material properties. In this study, an effective method to measure ELT is proposed and applied to 17-4 PH stainless steel for a nominal build layer thickness of 20 µm. The measured ELT was larger than 100 µm, which is far beyond the values reported in the literature. Results obtained from the current study show the effect of applying the ELT rather than the nominal build layer thickness in numerical modeling studies as well as understanding the governing physics in the LPBF process.",

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author = "Yahya Mahmoodkhani and Usman Ali and \{Imani Shahabad\}, Shahriar and \{Rani Kasinathan\}, Adhitan and Reza Esmaeilizadeh and Ali Keshavarzkermani and Ehsan Marzbanrad and Ehsan Toyserkani",

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T1 - On the measurement of effective powder layer thickness in laser powder-bed fusion additive manufacturing of metals

AU - Mahmoodkhani, Yahya

AU - Ali, Usman

AU - Imani Shahabad, Shahriar

AU - Rani Kasinathan, Adhitan

AU - Esmaeilizadeh, Reza

AU - Keshavarzkermani, Ali

AU - Marzbanrad, Ehsan

AU - Toyserkani, Ehsan

PY - 2019/6/1

Y1 - 2019/6/1

N2 - In laser powder-bed fusion (LPBF), the actual thickness of powder particles that spread on solidified zones, so-called effective layer thickness (ELT), is higher than the nominal layer thickness. The source cause of this discrepancy is the fact that powder particles substantially shrink after selective melting, followed by solidification. ELT, as an unknown parameter, depends on process parameters and material properties. In this study, an effective method to measure ELT is proposed and applied to 17-4 PH stainless steel for a nominal build layer thickness of 20 µm. The measured ELT was larger than 100 µm, which is far beyond the values reported in the literature. Results obtained from the current study show the effect of applying the ELT rather than the nominal build layer thickness in numerical modeling studies as well as understanding the governing physics in the LPBF process.

AB - In laser powder-bed fusion (LPBF), the actual thickness of powder particles that spread on solidified zones, so-called effective layer thickness (ELT), is higher than the nominal layer thickness. The source cause of this discrepancy is the fact that powder particles substantially shrink after selective melting, followed by solidification. ELT, as an unknown parameter, depends on process parameters and material properties. In this study, an effective method to measure ELT is proposed and applied to 17-4 PH stainless steel for a nominal build layer thickness of 20 µm. The measured ELT was larger than 100 µm, which is far beyond the values reported in the literature. Results obtained from the current study show the effect of applying the ELT rather than the nominal build layer thickness in numerical modeling studies as well as understanding the governing physics in the LPBF process.

KW - Additive manufacturing

KW - Effective layer thickness

KW - Laser–powder bed fusion

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