Skip to main content
Log in

Investigation of direct metal laser sintering downskin parameters’ sagging effect on microchannels

  • ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

Additive manufacturing technology is an innovative and advantageous production technology in producing microchannels, heat exchangers designed in complex geometries. Process parameters developed to provide production standardization and quality standards on production results are known. The study investigates the sagging effect of downskin parameters on the downfacing surfaces of microchannels designed in different geometries. In this context, the productions and SEM examinations and the geometric corrections obtained with the developed parameter sets are shared with tables and graphic studies. The direct metal laser sintering (DMLS) method was used in the parameter and production studies within the study’s scope.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6

Similar content being viewed by others

Availability of data and material

The authors confirm that the data and material supporting the findings of this work are available within the article.

References

  1. Aboulkhair NT, Everitt NM, Ashcroft I, Tuck C (2014) Reducing porosity in AlSi10Mg parts processed by selective laser melting. Addit Manuf 1:77–86. https://doi.org/10.1016/j.addma.2014.08.001

    Article  Google Scholar 

  2. Ameen W, Al-Ahmari A, Mohammed MK, Mian SH (2018) Manufacturability of overhanging holes using electron beam melting. Metals 8(6):1–24. https://doi.org/10.3390/met8060397

    Article  Google Scholar 

  3. Buchbinder D, Schleifenbaum H, Heidrich S, Meiners W, Bültmann J (2011) High power selective laser melting (HP DMLS) of aluminum parts. Phys Procedia 12(PART 1):271–278. https://doi.org/10.1016/j.phpro.2011.03.035

    Article  Google Scholar 

  4. Calignano F, Manfredi D, Ambrosio EP, Iuliano L, Fino P (2013) Influence of process parameters on surface roughness of aluminum parts produced by DMLS. Int J Adv Manuf Technol 67(9–12):2743–2751. https://doi.org/10.1007/s00170-012-4688-9

    Article  Google Scholar 

  5. Charles A, Elkaseer A, Thijs L, Hagenmeyer V, Scholz S (2019) Effect of process parameters on the generated surface roughness of down-facing surfaces in selective laser melting. Appl Sci (Switzerland) 9(6):1–13. https://doi.org/10.3390/app9061256

    Article  Google Scholar 

  6. EOS. 2018. “Material data sheet.” 2018. https://fathommfg.com/wp-content/uploads/2020/11/EOS_Aluminium_AlSi10Mg_en.pdf.

  7. Gao W, Zhang Y, Ramanujan D, Ramani K, Chen Y, Williams CB, Wang CCL, Shin YC, Zhang S, Zavattieri PD (2015) The status, challenges, and future of additive manufacturing in engineering. CAD Comput Aided Des 69:65–89. https://doi.org/10.1016/j.cad.2015.04.001

    Article  Google Scholar 

  8. Gaynor AT, Guest JK (2016) Topology optimization considering overhang constraints: eliminating sacrificial support material in additive manufacturing through design. Struct Multidiscip Optim 54(5):1157–1172. https://doi.org/10.1007/s00158-016-1551-x

    Article  MathSciNet  Google Scholar 

  9. Khan HM, Dirikolu MH, Koç E (2018) Parameters optimization for horizontally built circular profiles: numerical and experimental investigation. Optik 174(August):521–529. https://doi.org/10.1016/j.ijleo.2018.08.095

    Article  Google Scholar 

  10. Louvis E, Fox P, Sutcliffe CJ (2011) Selective laser melting of aluminium components. J Mater Process Technol 211(2):275–284. https://doi.org/10.1016/j.jmatprotec.2010.09.019

    Article  Google Scholar 

  11. Mingear J, Zhang B, Hartl D, Elwany A (2019) Effect of process parameters and electropolishing on the surface roughness of interior channels in additively manufactured nickel-titanium shape memory alloy actuators. Addit Manuf 27(April):565–575. https://doi.org/10.1016/j.addma.2019.03.027

    Article  Google Scholar 

  12. Mustafa SS, Lazoglu I (2020) A design framework for build process planning in DMLS. Progress in Addit Manuf 5(2):125–137. https://doi.org/10.1007/s40964-020-00110-0

    Article  Google Scholar 

  13. Olakanmi EO (2013) Selective laser sintering/melting (SLS/DMLS) of pure Al, Al-Mg, and Al-Si powders: effect of processing conditions and powder properties. J Mater Process Technol 213(8):1387–1405. https://doi.org/10.1016/j.jmatprotec.2013.03.009

    Article  Google Scholar 

  14. Paggi U, Sinico M, Thijs L, Dewulf W, and Van Hooreweder B. (2019) “Improving the dimensional accuracy of downfacing surfaces of additively manufactured parts.” Proceedings of the Special Interest Group Meeting on Advancing Precision in Additive Manufacturing, no. September: 35–38. https://lirias.kuleuven.be/2850508?limo=0.

  15. Peng T, Lv J, Majeed A, Liang X (2021) An experimental investigation on energy-effective additive manufacturing of aluminum parts via process parameter selection. J Clean Prod 279:123609. https://doi.org/10.1016/j.jclepro.2020.123609

    Article  Google Scholar 

  16. Pezzato L, Dabalà M, Gross S, Brunelli K (2020) Effect of microstructure and porosity of AlSi10Mg alloy produced by selective laser melting on the corrosion properties of plasma electrolytic oxidation coatings. Surf Coat Technol 404(October):126477. https://doi.org/10.1016/j.surfcoat.2020.126477

    Article  Google Scholar 

  17. Ramesh KN, Sharma TK, Rao GAP (2020) Latest advancements in heat transfer enhancement in the micro-channel heat sinks: a review. Arch Comput Methods Eng Springer Netherlands. https://doi.org/10.1007/s11831-020-09495-1

  18. Read N, Wang W, Essa K, Attallah MM (2015) Selective laser melting of AlSi10Mg alloy: process optimisation and mechanical properties development. Mater Des 65:417–424. https://doi.org/10.1016/j.matdes.2014.09.044

    Article  Google Scholar 

  19. Sanaei N, Fatemi A (2020) Analysis of the effect of surface roughness on fatigue performance of powder bed fusion additive manufactured metals. Theor Appl Fract Mech 108(May):102638. https://doi.org/10.1016/j.tafmec.2020.102638

    Article  Google Scholar 

  20. Snyder JC, Stimpson CK, Thole KA, Mongillo DJ (2015) Build direction effects on microchannel tolerance and surface roughness. J Mech Des, Transactions of the ASME 137(11):1–7. https://doi.org/10.1115/1.4031071

    Article  Google Scholar 

  21. Stimpson CK, Snyder JC, Thole KA, Mongillo D (2017) Scaling roughness effects on pressure loss and heat transfer of additively manufactured channels. J Turbomach 139(2):1–10. https://doi.org/10.1115/1.4034555

    Article  Google Scholar 

  22. Trevisan F, Calignano F, Lorusso M, Pakkanen J, Aversa A, Ambrosio EP, Lombardi M, Fino P, Manfredi D (2017) On the selective laser melting (DMLS) of the AlSi10Mg alloy: process, microstructure, and mechanical properties. Materials 10(1). https://doi.org/10.3390/ma10010076

  23. Ullah R, Akmal JS, Laakso SVA, Niemi E (2020) Anisotropy of additively manufactured AlSi10Mg: threads and surface integrity. Int J Adv Manuf Technol 107(9–10):3645–3662. https://doi.org/10.1007/s00170-020-05243-8

    Article  Google Scholar 

  24. Weingarten C, Buchbinder D, Pirch N, Meiners W, Wissenbach K, Poprawe R (2015) Formation and reduction of hydrogen porosity during selective laser melting of AlSi10Mg. J Mater Process Technol 221:112–120. https://doi.org/10.1016/j.jmatprotec.2015.02.013

    Article  Google Scholar 

  25. Whip B, Sheridan L, Gockel J (2019) The effect of primary processing parameters on surface roughness in laser powder bed additive manufacturing. Int J Adv Manuf Technol 103(9–12):4411–4422. https://doi.org/10.1007/s00170-019-03716-z

    Article  Google Scholar 

Download references

Funding

This study was prepared within the scope of “ALUTEAM-Aluminum Test Training and Research Center,” carried out by Fatih Sultan Mehmet Vakif University.

Author information

Authors and Affiliations

Authors

Contributions

Cemal İrfan Çalışkan: Design process, experimental, discussion result section authorship, CAD modeling, and table studies; Dr. Gökhan Özer: literature authorship, SEM laboratory works, editorial, and translation; Mert Coşkun: DMLS process parameter study, DMLS productions, literature study, and table studies; and Dr. Ebubekir Koç: coordinator.

Corresponding author

Correspondence to Cemal İrfan Çalışkan.

Ethics declarations

Ethical approval

The article follows the guidelines of the Committee on Publication Ethics (COPE) and involves no studies on human or animal subjects.

Consent to participate

Not applicable. The article involves no studies on humans.

Consent to publish

Not applicable. The article involves no studies on humans.

Competing interests

The authors declare no competing interests.

Additional information

Publisher’s note

Springer Nature remains neutral with regard to jurisdictional claims in published maps and institutional affiliations.

Rights and permissions

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Çalışkan, C.İ., Özer, G., Coşkun, M. et al. Investigation of direct metal laser sintering downskin parameters’ sagging effect on microchannels. Int J Adv Manuf Technol 114, 2567–2575 (2021). https://doi.org/10.1007/s00170-021-07057-8

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-021-07057-8

Keywords

Navigation