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The effect of primary processing parameters on surface roughness in laser powder bed additive manufacturing

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Abstract

Metal additive manufacturing (AM) is a method to create complex components in a layer-by-layer process. Laser powder bed fusion (LPBF) provides the ability to fabricate complex designs. Components with internal geometries have surfaces that are difficult to improve through post-processing and have been shown to be detrimental to mechanical performance. This work investigates the relationship between primary processing parameters, and surface roughness of nickel-based superalloy 718 fabricated on a LPBF AM machine. The surface roughness of components built using varied contour processing parameters was characterized using both nondestructive and destructive measurement techniques. Statistical correlations are presented between contour processing parameters and surface roughness height metrics along with general trends in the relationships. Results show that the destructive measurements are required to expose notch-like features that are obstructed by powder particles attached to the surface. However, nondestructive methods more easily provide a statistically significant sample size. Understanding the surface roughness can be used for further process optimization and to inform the qualification strategy for AM components.

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Acknowledgments

Thanks to Colt Montgomery from Carnegie Mellon University for assistance in manufacturing the components.

Funding

This study was funded and supported by the Turbine Engine Fatigue Facility of the US Air Force Research Laboratory and the Universal Technology Corporation.

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Authors and Affiliations

  1. Mechanical and Materials Engineering, Wright State University, 3640 Colonel Glenn Hwy, Dayton, OH, 45435, USA

    Bo Whip, Luke Sheridan & Joy Gockel

  2. Air Force Research Laboratory, Aerospace Systems Directorate, Turbine Engine Structural Integrity Branch, 2130 Eighth St. Rm 136, Wright Patterson, AFB, Dayton, OH, 45433, USA

    Luke Sheridan

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  1. Bo Whip
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  2. Luke Sheridan
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  3. Joy Gockel
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Correspondence to Joy Gockel.

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Whip, B., Sheridan, L. & Gockel, J. The effect of primary processing parameters on surface roughness in laser powder bed additive manufacturing. Int J Adv Manuf Technol 103, 4411–4422 (2019). https://doi.org/10.1007/s00170-019-03716-z

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  • DOI: https://doi.org/10.1007/s00170-019-03716-z

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