PDF(Pubmed)
Abstract：
This study investigates the potential benefits of integrating coarser particle size distributions (PSDs) of 45-106 µm into laser-based powder bed fusion of metals (PBF-LB/M), aiming to reduce costs while maintaining quality standards. Despite the considerable advantages of PBF-LB/M for producing intricate geometries with high precision, the high cost of metal powders remains a barrier to its widespread adoption. By exploring the use of coarser PSDs, particularly from electron beam-based powder bed fusion of metals (PBF-EB/M), significant cost-saving opportunities are identified. Through a comprehensive powder characterization, process analysis, and mechanical property evaluation, this study demonstrates that PBF-LB/M can effectively utilize coarser powders while achieving comparable mechanical properties as those produced with a 20-53 µm PSD. Adaptations to the process parameters enable the successful processing of coarser powders, maintaining high relative density components with minimal porosity. Additionally, market surveys reveal substantial cost differentials between PBF-LB/M and PBF-EB/M powders, indicating a 40% cost reduction potential for the feedstock material by integrating coarser PSDs into PBF-LB/M. Overall, this study provides valuable insights into the economic and technical feasibility of printing with coarser powders in PBF-LB/M, offering promising avenues for cost reduction without compromising quality, thus enhancing competitiveness and the adoption of the technology in manufacturing applications.
摘要：
这项研究调查了将45-106µm的较粗粒度分布（PSD）集成到基于激光的金属粉末床融合（PBF-LB/M）中的潜在好处，旨在降低成本，同时保持质量标准。尽管PBF-LB/M在高精度生产复杂的几何形状方面具有相当大的优势，金属粉末的高成本仍然是其广泛采用的障碍。通过探索使用较粗糙的PSD，特别是来自基于电子束的金属粉末床熔融（PBF-EB/M），确定了显著的节约成本的机会。通过全面的粉末表征，过程分析,和机械性能评估，这项研究表明，PBF-LB/M可以有效地利用较粗的粉末，同时实现与20-53µmPSD生产的机械性能相当。对工艺参数的调整能够成功加工较粗的粉末，保持高相对密度的组件与最小的孔隙率。此外,市场调查显示，PBF-LB/M和PBF-EB/M粉末之间存在巨大的成本差异，通过将较粗的PSD集成到PBF-LB/M中，表明原料具有40％的成本降低潜力。总的来说,这项研究为PBF-LB/M中使用较粗粉末印刷的经济和技术可行性提供了有价值的见解，在不影响质量的情况下提供有希望的降低成本途径，从而提高竞争力和在制造应用中采用该技术。
