Skip to main content

Advertisement

SpringerLink
Log in

Mechanical properties of laser powder bed fusion produced overhang parts with different support geometries: an experimental study

  • Full Research Article
  • Published:
Progress in Additive Manufacturing Aims and scope Submit manuscript

Abstract

Additive manufacturing technologies give engineers and researchers a high level of design freedom to produce complex components or entire assemblies previously impossible or impractical to manufacture by conventional means. Although additive manufacturing has many advantages compared to conventional machining, it has some drawbacks, two of which are higher surface roughness and dimensional inaccuracy of as-built part surfaces especially in overhang features. Support structures are one of the solutions to mitigate these drawbacks at a cost of additional post-processing efforts. The aim of the present study is to investigate the effect of different support geometries on the mechanical properties of laser powder bed fusion manufactured Inconel 718 overhang parts. The tested support geometries are comprised of several pieces to ease post-processing instead of using single-piece supports filling all over the overhang surface. One of the tested support structures is contactless support with no direct contact between the part and the support itself. The others are tooth support where the contact is on the tooth faces and line support where the contact is along a line. The thickness of each support piece and the spacing between the two support pieces were used as design variables. The dimensional accuracy of printed specimens with respect to the computer-aided geometry, distortion of overhang features, microhardness through the thickness, microstructural changes of overhang surface, and surface roughness of overhang features was experimentally evaluated. The results revealed that support type, support spacing and support thickness directly affect the performance characteristics used in this study.

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

Access this article

Log in via an institution

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

Instant access to the full article PDF.

Institutional subscriptions

Fig. 1
Fig. 2
Fig. 3
Fig. 4
Fig. 5
Fig. 6
Fig. 7
Fig. 8
Fig. 9
Fig. 10
Fig. 11
Fig. 12
Fig. 13
Fig. 14
Fig. 15
Fig. 16
Fig. 17
Fig. 18
Fig. 19
Fig. 20
Fig. 21
Fig. 22
Fig. 23
Fig. 24
Fig. 25
Fig. 26
Fig. 27
Fig. 28

Similar content being viewed by others

Data availability

Data sets generated during the current study are available from the corresponding author on reasonable request.

References

  1. Zhong RY, Xu X, Klotz E, Newman ST (2017) Intelligent manufacturing in the context of industry 4.0: a review. Engineering 3(5):616–630. https://doi.org/10.1016/J.ENG.2017.05.015

    Article  Google Scholar 

  2. Avila JD, Bose S, Bandyopadhyay A (2018) Additive manufacturing of titanium and titanium alloys for biomedical applications. In: Froes FH, Qian M (eds) Titanium in medical and dental applications. Woodhead Publishing Series in Biomaterials, pp 325–343

    Google Scholar 

  3. Herzog D, Seyda V, Wycisk E, Emmelmann C (2016) Additive manufacturing of metals. Acta Mater 117:371–392. https://doi.org/10.1016/j.actamat.2016.07.019

    Article  Google Scholar 

  4. Flores I, Kretzschmar N, Azman AH, Chekurov S, Pedersen DB, Chaudhuri A (2020) Implications of lattice structures on economics and productivity of metal powder bed fusion. Addit Manuf 31:100947. https://doi.org/10.1016/j.addma.2019.100947

    Article  Google Scholar 

  5. Zakrzewski T, Kozak J, Witt M, Dębowska-Wąsak M (2020) Dimensional analysis of the effect of SLM parameters on surface roughness and material density. Procedia CIRP 95:115–120. https://doi.org/10.1016/j.procir.2020.01.182

    Article  Google Scholar 

  6. Xiao Z, Yang Y, Xiao R, Bai Y, Song C, Wang D (2018) Evaluation of topology optimized lattice structures manufactured via selective laser melting. Mater Des 143:27–37. https://doi.org/10.1016/j.matdes.2018.01.023

    Article  Google Scholar 

  7. Ma Z, Zhang DZ, Liu F, Jiang J, Zhao M, Zhang T (2018) Lattice structures of Cu–Cr–Zr copper alloy by selective laser melting: Microstructures, mechanical properties and energy absorption. Mater Des 187:108406

    Article  Google Scholar 

  8. 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 9:1256. https://doi.org/10.3390/app9061256

    Article  Google Scholar 

  9. Maamoun AH, Xue YF, Elbestawi MA, Veldhuis SC (2018) Effect of selective laser melting process parameters on the quality of al alloy parts: powder characterization, density, surface roughness, and dimensional accuracy. Materials 11:2343. https://doi.org/10.3390/ma11122343

    Article  Google Scholar 

  10. Pehlivan E, Roudnicka M, Dzugan J, Koukolikova M, Králík V, Seifi M, Lewandowski JJ, Dalibor D, Daniel M (2020) Effects of build orientation and sample geometry on the mechanical response of miniature CP-Ti Grade 2 strut samples manufactured by laser powder bed fusion. Addit Manuf 35:101403. https://doi.org/10.1016/j.addma.2020.101403

    Article  Google Scholar 

  11. Leon A, Aghion E (2017) Effect of surface roughness on corrosion fatigue performance of AlSi10Mg alloy produced by selective laser melting (SLM). Mater Charact 131:188–194. https://doi.org/10.1016/j.matchar.2017.06.029

    Article  Google Scholar 

  12. Ren D, Li S, Wang H, Hou W, Hao Y, Jin W, Yang R, Devesh R, Misra K, Murr LE (2019) Fatigue behavior of Ti-6Al-4V cellular structures fabricated by additive manufacturing technique. J Mater Sci Technol 35:285–294. https://doi.org/10.1016/j.jmst.2018.09.066

    Article  Google Scholar 

  13. Spierings AB, Starr TL, Wegener K (2013) Fatigue performance of additive manufactured metallic parts. Rapid Prototyp J 19:88–94. https://doi.org/10.1108/13552541311302932

    Article  Google Scholar 

  14. Jamshidinia M, Wang L, Tong W, Ajlouni R, Kovacevic R (2015) Fatigue properties of a dental implant produced by electron beam melting (EBM). J Mater Process Technol 226:255–263. https://doi.org/10.1016/j.jmatprotec.2015.07.013

    Article  Google Scholar 

  15. Vayssette B, Saintier N, Brugger C, El May M, Pessard E (2018) Surface roughness of Ti-6Al-4V parts obtained by SLM and EBM: effect on the high cycle fatigue life. Procedia Eng 213:89–97. https://doi.org/10.1016/j.proeng.2018.02.010

    Article  Google Scholar 

  16. Vayssette B, Saintier N, Brugger C, El May M, Pessard E (2019) Numerical modelling of surface roughness effect on the fatigue behavior of Ti–6Al-4V obtained by additive manufacturing. Int J Fatigue 123:180–195. https://doi.org/10.1016/j.ijfatigue.2019.02.014

    Article  Google Scholar 

  17. Alfaify A, Saleh M, Abdullah FM, Al-Ahmari AM (2020) Design for additive manufacturing: a systematic review. Sustainability 12:7936. https://doi.org/10.3390/su12197936

    Article  Google Scholar 

  18. Zhang K, Fu G, Zhang P, Ma Z, Mao Z, Zhang DZ (2019) Study on the geometric design of supports for overhanging structures fabricated by selective laser melting. Materials 12:27. https://doi.org/10.3390/ma12010027

    Article  Google Scholar 

  19. Leary M (2017) Surface roughness optimisation for selective laser melting (SLM): accommodating relevant and irrelevant surfaces. In: Brandt M (ed) Laser additive manufacturing. Woodhead Publishing, pp 99–118. https://doi.org/10.1016/B978-0-08-100433-3.00004-X

    Chapter  Google Scholar 

  20. Emmelmann C, Herzog D, Kranz J (2017) Design for laser additive manufacturing. In: Brandt M (ed) laser additive manufacturing. Woodhead Publishing, pp 259–279. https://doi.org/10.1016/B978-0-08-100433-3.00010-5

    Chapter  Google Scholar 

  21. Huang R, Dai N, Cheng X, Wang L (2020) Topology optimization of lattice support structures for heat conduction in selective laser melting. Int J Adv Manuf Technol 109:1841–1851. https://doi.org/10.1007/s00170-020-05741-9

    Article  Google Scholar 

  22. Järvinen JP, Matilainen V, Li X, Piili H, Salminen A, Mäkelä I, Nyrhilä O (2014) Characterization of effect of support structures in laser additive manufacturing of stainless steel. Phys Procedia 56:72–81. https://doi.org/10.1016/j.phpro.2014.08.099

    Article  Google Scholar 

  23. Umer U, Ameen W, Abidi MH, Moiduddin K, Alkhalefah H, Alkahtani M, Al-Ahmari A (2019) Modeling the effect of different support structures in electron beam melting of titanium alloy using finite element models. Metals 9:806. https://doi.org/10.3390/met9070806

    Article  Google Scholar 

  24. Cooper K, Steele P, Cheng B, Chou K (2018) Contact-free support structures for part overhangs in powder-bed metal additive manufacturing. Inventions 3(1):2. https://doi.org/10.3390/inventions3010002

    Article  Google Scholar 

  25. Cheng B, Chou YK (2017) Overhang support structure design for electron beam additive manufacturing. In: Proceedings of the ASME 2017 12th International Manufacturing Science and Engineering Conference, June 4–8, Los Angeles, CA, USA

  26. Cheng B, Chou K (2020) A numerical investigation of support structure designs for overhangs in powder bed electron beam additive manufacturing. J Manuf Process 49:187–195. https://doi.org/10.1016/j.jmapro.2019.11.018

    Article  Google Scholar 

  27. Poyraz Ö, Yasa E, Akbulut G, Orhangül A, Pilatin S (2015) Investigation of support structures for direct metal laser sintering (DMLS) of In625 Parts. In: Solid Freeform Fabrication Symposium, Austin, Texas, USA, pp. 560–574

  28. Calignano F (2014) Design optimization of supports for overhanging structures in aluminum and titanium alloys by selective laser melting. Mater Des 64:203–213. https://doi.org/10.1016/j.matdes.2014.07.043

    Article  Google Scholar 

  29. Ameen W, Al-Ahmari A, Mohammed MK (2019) Self-supporting overhang structures produced by additive manufacturing through electron beam melting. Int J Adv Manuf Technol 104:2215–2232. https://doi.org/10.1007/s00170-019-04007-3

    Article  Google Scholar 

  30. Ameen W, Mohammed MK, Al-Ahmari A, Ahmed N, Mian SH (2020) Investigation of support structure parameters and their affects during additive manufacturing of Ti6Al4V alloy via electron beam melting. Proc Inst Mech Eng, Part L: J Mater Des Appl. https://doi.org/10.1177/1464420720981668

    Article  Google Scholar 

  31. Kurzynowski T, Stopyra W, Gruber K, Ziółkowski G, Kuźnicka B, Chlebus E (2019) Effect of scanning and support strategies on relative density of SLM-ed H13 steel in relation to specimen size. Materials 12:239. https://doi.org/10.3390/ma12020239

    Article  Google Scholar 

  32. Kouraytem N, Chanut RA, Watring DS, Loveless T, Varga J, Spear AD, Kingstedt OT (2020) Dynamic-loading behavior and anisotropic deformation of pre-and post-heat-treated In718 fabricated by laser powder bed fusion. Addit Manuf 33:101083. https://doi.org/10.1016/j.addma.2020.101083

    Article  Google Scholar 

  33. Bartolomeu F, Dourado N, Pereira F, Alves N, Miranda G, Silva FS (2020) Additive manufactured porous biomaterials targeting orthopedic implants: A suitable combination of mechanical, physical and topological properties. Mater Sci Eng C 107:110342. https://doi.org/10.1016/j.msec.2019.110342

    Article  Google Scholar 

  34. Bartolomeu F, Fonseca J, Peixinho N, Alves N, Gasik M, Silva FS, Miranda G (2019) Predicting the output dimensions, porosity and elastic modulus of additive manufactured biomaterial structures targeting orthopedic implants. J Mech Behav Biomed Mater 99:104–117. https://doi.org/10.1016/j.jmbbm.2019.07.023

    Article  Google Scholar 

  35. Ran Q, Yang W, Hu Y, Shen X, Yu Y, Xiang Y, Cai K (2018) Osteogenesis of 3D printed porous Ti6Al4V implants with different pore sizes. J Mech Behav Biomed Mater 84:1–11. https://doi.org/10.1016/j.jmbbm.2018.04.010

    Article  Google Scholar 

  36. Sing SL, Miao Y, Wiria FE, Yeong WY (2016) Manufacturability and mechanical testing considerations of metallic scaffolds fabricated using selective laser melting: a review. Biomed Sci Eng 2(11):18–24. https://doi.org/10.4081/bse.2016.11

    Article  Google Scholar 

  37. Gülcan O, Günaydın K, Çelik A, Yasa E (2022) The effect of contactless support parameters on the mechanical properties of laser powder bed fusion produced overhang parts. Int J Adv Manuf Technol 122:3235–3253. https://doi.org/10.1007/s00170-022-10135-0

    Article  Google Scholar 

  38. Gülcan O, Simsek U, Cokgunlu O, Özdemir M, Şendur P, Yapici GG (2022) Effect of build parameters on the compressive behavior of additive manufactured CoCrMo lattice parts based on experimental design. Metals 12(7):1104. https://doi.org/10.3390/met12071104

    Article  Google Scholar 

  39. Gülcan O, Günaydın K (2022) Reducing support material usage in laser powder bed fusion parts: segmented passive support design for sustainable aviation. Towards Sustainable Aviation Summit, 18–20 October, Toulouse, France

  40. Newton L, Senin N, Gomez C, Danzl R, Helmli F, Blunt L, Leach R (2019) Areal topography measurement of metal additive surfaces using focus variation microscopy. Addit Manuf 25:365–389. https://doi.org/10.1016/j.addma.2018.11.013

    Article  Google Scholar 

  41. Tonelli L, Fortunato A, Ceschini L (2020) CoCr alloy processed by selective laser melting (SLM): effect of laser energy density on microstructure, surface morphology, and hardness. J Manuf Proces 52:106–119. https://doi.org/10.1016/j.jmapro.2020.01.052

    Article  Google Scholar 

  42. Anwar AB, Ibrahim IH, Pham Q-C (2019) Spatter transport by inert gas flow in selective laser melting: a simulation study. Powder Technol 352:103–116. https://doi.org/10.1016/j.powtec.2019.04.044

    Article  Google Scholar 

  43. Gunenthiram V, Peyre P, Schneider M, Dal M, Coste F, Koutiri I, Fabbro R (2018) Experimental analysis of spatter generation and melt-pool behavior during the powder bed laser beam melting process. J Mater Process Technol 251:376–386. https://doi.org/10.1016/j.jmatprotec.2017.08.012

    Article  Google Scholar 

  44. Schniedenharn M, Wiedemann F, Schleifenbaum JH (2018) Visualization of the shielding gas flow in SLM machines by space-resolved thermal anemometry. Rapid Prototyp J 24(8):1296–1304

    Article  Google Scholar 

  45. Li R, Liu J, Shi Y, Wang L, Jiang W (2012) Balling behavior of stainless steel and nickel powder during selective laser melting process. Int J Adv Manuf Technol 59:1025–1035. https://doi.org/10.1007/s00170-011-3566-1

    Article  Google Scholar 

  46. Boutaous M, Liu X, Siginer DA, Xin S (2021) Balling phenomenon in metallic laser based 3D printing process. Int J Therm Sci 167:107011. https://doi.org/10.1016/j.ijthermalsci.2021.107011

    Article  Google Scholar 

  47. Dwivedi S, Dixit AR, Das AK (2022) Wetting behavior of selective laser melted (SLM) bio-medical grade stainless steel 316L. Mater Today: Proc 56(1):46–50. https://doi.org/10.1016/j.matpr.2021.12.046

    Article  Google Scholar 

  48. Karabulut Y, Tascioglu E, Kaynak Y (2021) Heat treatment temperature-induced microstructure, microhardness and wear resistance of Inconel 718 produced by selective laser melting additive manufacturing. Optik 227:163907. https://doi.org/10.1016/j.ijleo.2019.163907

    Article  Google Scholar 

  49. Seede R, Mostafa A, Brailovski V, Jahazi M, Medraj M (2018) Microstructural and microhardness evolution from homogenization and hot isostatic pressing on selective laser melted Inconel 718: structure, texture, and phases. J Manuf Mater Process 2(2):30. https://doi.org/10.3390/jmmp2020030

    Article  Google Scholar 

  50. Zhang B, Wang P, Chew Y, Wen Y, Zhang M, Wang P, Bi G, Wei J (2020) Mechanical properties and microstructure evolution of selective laser melting Inconel 718 along building direction and sectional dimension. Mater Sci Eng: A 794:139941. https://doi.org/10.1016/j.msea.2020.139941

    Article  Google Scholar 

  51. Qi M, Huang S, Ma Y, Youssef SS, Zhang R, Qiu J, Lei J, Yang R (2021) Columnar to equiaxed transition during β heat treatment in a near β alloy by laser additive manufacture. J Mater Res Technol 13:1159–1168. https://doi.org/10.1016/j.jmrt.2021.05.057

    Article  Google Scholar 

Download references

Funding

This study was carried out under the Scientific and Technological Council of Turkey (TUBITAK) Technology and Innovation Support Program (Grant Number: 5158001).

Author information

Authors and Affiliations

  1. General Electric Aviation, Additive Design, Kocaeli, Turkey

    Orhan Gülcan, Kadir Günaydın & Alican Çelik

  2. Mechanical Engineering Department, Eskişehir Osmangazi University, Eskişehir, Turkey

    Evren Yasa

Authors
  1. Orhan Gülcan
    View author publications

    You can also search for this author in PubMed Google Scholar

  2. Kadir Günaydın
    View author publications

    You can also search for this author in PubMed Google Scholar

  3. Alican Çelik
    View author publications

    You can also search for this author in PubMed Google Scholar

  4. Evren Yasa
    View author publications

    You can also search for this author in PubMed Google Scholar

Contributions

The study conception and design were performed by OG. Material preparation, data collection and analysis were performed by OG, KG and AÇ. Discussion was performed by OG, KG and EY. The first draft of the manuscript was written by Orhan Gülcan and all authors commented on previous versions of the manuscript. All authors read and approved the final manuscript.

Corresponding author

Correspondence to Orhan Gülcan.

Ethics declarations

Conflict of interest

The authors declare no conflict of interest. The funders had no role in the design of the study; in the collection, analyses, or interpretation of data; in the writing of the manuscript, or in the decision to publish the results. The authors have no competing interests to declare that are relevant to the content of this article.

Additional information

Publisher's Note

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

Rights and permissions

Springer Nature or its licensor (e.g. a society or other partner) holds exclusive rights to this article under a publishing agreement with the author(s) or other rightsholder(s); author self-archiving of the accepted manuscript version of this article is solely governed by the terms of such publishing agreement and applicable law.

Reprints and permissions

About this article

Check for updates. Verify currency and authenticity via CrossMark

Cite this article

Gülcan, O., Günaydın, K., Çelik, A. et al. Mechanical properties of laser powder bed fusion produced overhang parts with different support geometries: an experimental study. Prog Addit Manuf 9, 211–229 (2024). https://doi.org/10.1007/s40964-023-00443-6

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s40964-023-00443-6

Keywords

Search

Navigation