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Experimental and numerical assessment of surface roughness for Ti6Al4V lattice elements in selective laser melting

  • Ahmad Alghamdi
  • David Downing
  • Matthew McMillan
  • Milan Brandt
  • Ma Qian
  • Martin LearyEmail author
ORIGINAL ARTICLE

Abstract

Additive manufacturing (AM) such as selective laser melting (SLM) enables the fabrication of complex lattice structures. These lattice structures are efficiently fabricated for a variety of applications, such as aerospace components and biomedical implants. The SLM process inherently introduces local temperature fields, resulting in local thermal defects, including porosity, partially fused particles, and dimensional errors. These defects introduce variation between the intended and manufactured geometries. This research provides an extensive experimental and numerical assessment of these geometric effects on individual lattice strut elements. These effects are quantified by systematic methods, allowing roughness of SLM lattice struts to be correlated with associated geometric control factors, i.e. length of strut, Ls, diameter of strut, Ds, and manufacturing inclination angle, α. Robust correlation is found between experimental and numerical data; resulting in a methodology for a priori prediction of thermally induced defects based on input geometry.

Keywords

Surface roughness Lattice CAE Thermal simulation FEM Additive manufacturing 

Notes

Acknowledgements

This research was conducted by the Australian Research Council Industrial Transformation Training Centre in Additive Biomanufacturing (IC160100026) https://www.additivebiomanufacturing.org. The authors would like to acknowledge the support from RMIT's Centre for Additive Manufacturing.

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Copyright information

© Springer-Verlag London Ltd., part of Springer Nature 2019

Authors and Affiliations

  • Ahmad Alghamdi
    • 1
  • David Downing
    • 1
    • 2
  • Matthew McMillan
    • 1
  • Milan Brandt
    • 1
    • 2
  • Ma Qian
    • 1
  • Martin Leary
    • 1
    • 2
    Email author
  1. 1.RMIT Center for Additive ManufacturingRMIT UniversityMelbourneAustralia
  2. 2.ARC Training Centre in Additive BiomanufacturingMelbourneAustralia

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