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Permeability and Mechanical Properties of Additively Manufactured Porous Maraging 300 Steel

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Abstract

Porous metallic materials are materials that have closed cell or open cell pores within their microstructure and have unique properties such as permeability and high stiffness-to-weight ratio depending on the type of the pore. Open cell pores in porous metallic materials allow minuscule particles such as air to pass through, giving it its permeability property. Permeability in porous metallic materials can further serve as air vents in injection moulds allowing the process to have a better surface finish and also dispel heat from the system better. Additive manufacturing can manufacture these materials to save time and cost and provides more intricate designs compared to traditional manufacturing. This study aims to manufacture maraging 300 steel with tailored porosity by controlling the processing parameters in the selective laser melting (SLM) process. The effect of each parameter on relative density was determined using an L9 orthogonal array through Taguchi’s Design of Experiments. It was found that hatch spacing had the largest effect, followed by laser power, layer thickness, and scanning speed. Regression modelling found that the equation can provide a good prediction of the relative density. When the processing parameters were related to energy density function, regression equation utilising energy density has a better performance, but its use is restricted to the range of energy density reported. The materials became permeable when the relative density is less than 95%. Permeability increases linearly with a sharp increase at a relative density below 80% due to the high volume of open pores. In terms of mechanical properties, both compression modulus and yield strength decrease with decreasing relative density. The method shown here can be applied to produce, within the same part, a combination of porous and non-porous sections in the same manufacturing process.

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Funding

This work was supported by Taylor’s Internal Research Grant Scheme - Emerging Research Funding Scheme from Taylor’s University, Malaysia (TRGS/ERFS/2/2018/SOE/005).

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Authors and Affiliations

  1. School of Computer Science and Engineering, Taylor’s University, No. 1 Jalan Taylor’s, 47500, Subang Jaya, Malaysia

    Shen Huei Wynton Lee & Hui Leng Choo

  2. SLM Solutions Singapore Pte Ltd, 25 International Business Park, #02-15/17 German Centre, Singapore, 609916, Singapore

    Sui Him Mok

  3. Omni Mold Ltd, 51 Joo Koon Circle, Singapore, 629069, Singapore

    Xin Yi Cheng

  4. Faculty of Mechanical Engineering, UiTM Shah Alam, Shah Alam, Selangor, Malaysia

    Yupiter Harangan Prasada Manurung

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  1. Shen Huei Wynton Lee
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  2. Hui Leng Choo
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Correspondence to Hui Leng Choo.

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Lee, S.H.W., Choo, H.L., Mok, S.H. et al. Permeability and Mechanical Properties of Additively Manufactured Porous Maraging 300 Steel. Lasers Manuf. Mater. Process. 8, 28–44 (2021). https://doi.org/10.1007/s40516-020-00134-y

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