Abstract
The conventional scanning strategies based on linear trajectories in Laser Powder Bed Fusion (LPBF) are highly limited for processing novel materials. In order to manage the energy input and exploit a higher feature resolution, novel scan strategies are required, capable of exploiting the flexibility enabled by the fast modulation capabilities of contemporary fiber laser sources. Zinc and its alloys are among these challenging materials for LPBF aimed to be used in customized biodegradable implants. LPBF of Zn is notoriously difficult to process due to excessive vaporisation which generates high porosity. Accordingly, in this study an innovative LPBF processing strategy based on Single Point Exposure (SPE) was developed. The control over the energy input via single spot exposure allowed to suppress excessive vapour and spark formation typical to Zn alloys. The dynamics of the novel process and its parameters were investigated employing open LPBF platforms and high-speed imaging. Fully dense struts with diameters lower than 300 µm were achieved to produce Zn alloy lattice structures, confirming the effectiveness of the innovative SPE strategy for high precision deposition of challenging materials.
Graphical Abstract
This is a preview of subscription content, log in via an institution to check access.
Access this chapter
Tax calculation will be finalised at checkout
Purchases are for personal use only
References
Schmidt M, Merklein M, Bourell D, Dimitrov D, Hausotte T, Wegener K, Overmeyer L, Vollertsen F, Levy GN (2017) Laser based additive manufacturing in industry and academia. CIRP Ann 66:561–583
Carluccio D, Demir AG, Bermingham MJ, Dargusch MS (2020) Challenges and opportunities in the selective laser melting of biodegradable metals for load-bearing bone scaffold applications. Metall Mater Trans A Phys Metall Mater Sci 51:3311–3334
Li Y, Pavanram P, Zhou J, Lietaert K, Taheri P, Li W, San H, Leeflang MA, Mol JMC, Jahr H, Zadpoor AA (2020) Additively manufactured biodegradable porous zinc. Acta Biomater 101:609–623
Chen Y, Wen P, Voshage M, Jauer L, Qin Y, Schleifenbaum JH, Poprawe R (2019) Laser additive manufacturing of Zn metal parts for biodegradable implants: effect of gas flow on evaporation and formation quality. J Laser Appl 31:022304
Demir AG, Monguzzi L, Previtali B (2017) Selective laser melting of pure Zn with high density for biodegradable implant manufacturing. Addit Manuf 15:20–28
Wen P, Jauer L, Voshage M, Chen Y, Poprawe R, Schleifenbaum JH (2018) Densification behavior of pure Zn metal parts produced by selective laser melting for manufacturing biodegradable implants. J Mater Process Technol 258:128–137
Grasso M, Demir AG, Previtali B, Colosimo BM (2018) In situ monitoring of selective laser melting of zinc powder via infrared imaging of the process plume. Robot Comput Integr Manuf 49:229–239
Mills KC (2002) Recommended values of thermophysical properties for selected commercial alloys. Woodhead Publishing
Caprio L, Demir AG, Previtali B (2018) Comparative study between CW and PW emissions in selective laser melting. J Laser Appl 30:32305
Matsunawa A, Mizutani M, Katayama S, Seto N (2003) Porosity formation mechanism and its prevention in laser welding. Weld Int 17:431–437
Schaefer M, Kessler S, Scheible P, Graf T (2017) Modulation of the laser power to prevent hot cracking during laser welding of tempered steel. J Laser Appl 29:042008
Bruna-rosso C, Demir AG, Previtali B (2018) Selective laser melting finite element modeling: validation with high-speed imaging and lack of fusion defects prediction. Mater Des 156:143–153
Onal E, Medvedev AE, Leeflang MA, Molotnikov A, Zadpoor AA (2019) Novel microstructural features of selective laser melted lattice struts fabricated with single point exposure scanning. Addit Manuf 29
Ghouse S, Babu S, Van Arkel RJ, Nai K, Hooper PA, Jeffers JRTT, Van Arkel RJ, Nai K, Hooper PA, Jeffers JRTT (2017) The influence of laser parameters and scanning strategies on the mechanical properties of a stochastic porous material. Mater Des 131:498–508
Tsopanos S, Mines RAW, McKown S, Shen Y, Cantwell WJ, Brooks W, Sutcliffe CJ (2010) The influence of processing parameters on the mechanical properties of selectively laser melted stainless steel microlattice structures. J Manuf Sci Eng Trans ASME 132:0410111–04101112
Qin Y, Wen P, Voshage M, Chen Y, Scher PG, Jauer L, Xia D, Guo H, Zheng Y, Schleifenbaum JH (2019) Additive manufacturing of biodegradable Zn-xWE43 porous scaffolds: formation quality, microstructure and mechanical properties. Mater Des 181
Li Y, Li W, Bobbert FSL, Lietaert K, Dong JH, Leeflang MA, Zhou J, Zadpoor AA (2020) Corrosion fatigue behavior of additively manufactured biodegradable porous zinc. Acta Biomater 106:439–449
Maconachie T, Leary M, Lozanovski B, Zhang X, Qian M, Faruque O, Brandt M (2019) SLM lattice structures: poperties, performance, applications and challenges. Mater Des 183:108137
Wauthle R, Vrancken B, Beynaerts B, Jorissen K, Schrooten J, Kruth JP, Van Humbeeck J (2015) Effects of build orientation and heat treatment on the microstructure and mechanical properties of selective laser melted Ti6Al4V lattice structures. Addit Manuf 5:77–84
Semak VV, Hopkins JA, Mccay MH, Mccay TD (1994) A concept for a hydrodynamic model of keyhole formation and support during laser welding. Int Congr Appl Lasers Electro-Optics 641–650
Liu JM (1982) Simple technique for measurements of pulsed Gaussian-beam spot sizes. Opt Lett 7:196
Fischer P, Karapatis N, Romano V, Glardon R, Weber HP (2002) A model for the interaction of near-infrared laser pulses with metal powders in selective laser sintering. Appl Phys A-Mater Sci Process 74:467–474
Author information
Authors and Affiliations
Corresponding author
Editor information
Editors and Affiliations
Rights and permissions
Copyright information
© 2022 The Author(s), under exclusive license to Springer Nature Switzerland AG
About this chapter
Cite this chapter
Caprio, L., Guaglione, F., Demir, A.G. (2022). Development of Single Point Exposure Strategy to Suppress Vapour Formation During the Laser Powder Bed Fusion of Zinc and Its Alloys. In: Carrino, L., Tolio, T. (eds) Selected Topics in Manufacturing. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-82627-7_7
Download citation
DOI: https://doi.org/10.1007/978-3-030-82627-7_7
Published:
Publisher Name: Springer, Cham
Print ISBN: 978-3-030-82626-0
Online ISBN: 978-3-030-82627-7
eBook Packages: EngineeringEngineering (R0)