Abstract
Diode area melting (DAM) is a new additive manufacturing process that utilises customised architectural arrays of low-power laser diode emitters for high-speed parallel processing of metallic feedstock. The laser diodes operate at shorter laser wavelengths (808 nm) than conventional SLM fibre lasers (1064 nm) theoretically enabling more efficient energy absorption for specific materials. This investigation presents the first work investigating the melt pool properties and thermal effects of the multi-laser DAM process, modelling generated melt pools the unique thermal profiles created along a powder bed during processing. Using this approach process, optimisation can be improved by analysing this thermal temperature distribution, targeting processing conditions that induce full melting for variable powder layer thicknesses. In this work, the developed thermal model simulates the DAM processing of 316L stainless steel and is validated with experimental trials. The simulation indicates that multi-laser DAM methodology can reduce residual stress formation compared to the single point laser scanning methods used during selective laser melting.
Article PDF
Similar content being viewed by others
Avoid common mistakes on your manuscript.
References
Zavala-Arredondo M, Boone N, Willmott J, Childs DTD, Ivanov P, Groom KM, Mumtaz K (2017) Laser diode area melting for high speed additive manufacturing of metallic components. Mater Des 117:305–315
Zavala-Arredondo M, Groom KM, and Mumtaz K (2017) Diode area melting single-layer parametric analysis of 316L stainless steel powder. Int J Adv Manuf Technol 1–14
Casavola C, Campanelli L, and Pappalettere C (2008) Experimental analysis of residual stresses in the selective laser melting process. in Proceedings of the XIth International Congress and Exposition 3:1479–1486
Withers PJ, Bhadeshia HKDH (2001) Residual stress. Part 2—nature and origins. Mater Sci Technol 17(4):366–375
Mercelis P, Kruth J, Kruth J-P (2006) Residual stresses in selective laser sintering and selective laser melting. Rapid Prototyp J 12(3):254–265
Li L, Lough C, Replogle A, Bristow D, Landers R, and Kinzel E (2017) Thermal modeling of 304L stainless steel selective laser melting, in Solid Freedorm fabrication, pp 1068–1081
Ali H (2017) Evolution of residual stress in Ti6Al4V components fabricated using selective laser melting
Smurov IY, Dubenskaya MA, Zhirnov IV, Teleshevskii VI (2016) Determination of the true temperature during selective laser melting of metal powders based on measurements with an infrared camera. Meas Tech 59(9):971–974
Mills KC (2002) Recommended values of thermophysical properties for selected commercial alloys. Woodhead
Yadroitsev I, Yadroitsava I (2015) Evaluation of residual stress in stainless steel 316L and Ti6Al4V samples produced by selective laser melting. Virtual Phys Prototyp 10(2):67–76
Elmer JW, Allen SM, Eagar TW (1989) Microstructural development during solidification of stainless steel alloys. Metall Trans A 20(10):2117–2131
Li R, Shi Y, Liu J, Yao H, Zhang W (2009) Effects of processing parameters on the temperature field of selective laser melting metal powder. Powder Metall Met Ceram 48(3–4):186–195
Kempen K, Vrancken B, Thijs L, Buls S, Van Humbeeck J, and Kruth J-P (2013) Lowering thermal gradients in Selective Laser melting by pre-heating the baseplate
Ali H, Ma L, Ghadbeigi H, Mumtaz K (2017) In-situ residual stress reduction, martensitic decomposition and mechanical properties enhancement through high temperature powder bed pre-heating of selective laser melted Ti6Al4V. Mater Sci Eng A 695:211–220
Kamath C, El-dasher B, Gallegos GF, King WE, Sisto A (2013) Density of additively-manufactured, 316L SS parts using laser powder-bed fusion at powers up to 400W. Lawrence Livermore National Laboratory, Livermore
Vaithilingam J, Goodridge RD, Hague RJM, Christie SDR, Edmondson S (2016) The effect of laser remelting on the surface chemistry of Ti6al4V components fabricated by selective laser melting. J Mater Process Technol 232:1–8
Parry L, Ashcroft IA, Wildman RD (2016) Understanding the effect of laser scan strategy on residual stress in selective laser melting through thermo-mechanical simulation. Addit Manuf 12:1–15
Foroozmehr A, Badrossamay M, Foroozmehr E, Golabi I (2016) Finite element simulation of selective laser melting process considering optical penetration depth of laser in powder bed. Mater Des 89:255–263
Roberts IA (2012) Investigation of residual stresses in the laser melting of metal powders in additive layer manufacturing. University of Wolverhampton, Wolverhampton
Shi Y, Shen H, Yao Z, Hu J (2007) Temperature gradient mechanism in laser forming of thin plates. Opt Laser Technol 39:858–863
Zavala Arredondo MA (2017) Diode area melting use of high power diode lasers in additive manufacturing of metallic components. University of Sheffield, Sheffield
Acknowledgements
The authors would like to acknowledge support from a UK Engineering & Physical Sciences Research Council (EP/ K503812/1) IIKE Proof of Concept award and the Future Manufacturing Hub in Manufacture using Advanced Powder Processes (MAPP) (EP/P006566/1). Also acknowledge support from the Science and Technology National Council (CONACYT) of Mexico.
Author information
Authors and Affiliations
Corresponding author
Rights and permissions
Open Access This article is distributed under the terms of the Creative Commons Attribution 4.0 International License (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted use, distribution, and reproduction in any medium, provided you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons license, and indicate if changes were made.
About this article
Cite this article
Zavala-Arredondo, M., Ali, H., Groom, K.M. et al. Investigating the melt pool properties and thermal effects of multi-laser diode area melting. Int J Adv Manuf Technol 97, 1383–1396 (2018). https://doi.org/10.1007/s00170-018-2038-2
Received:
Accepted:
Published:
Issue Date:
DOI: https://doi.org/10.1007/s00170-018-2038-2