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Effects of powder reuse on the microstructure and mechanical behaviour of Al-Mg-Sc-Zr alloy processed by laser powder bed fusion (LPBF)
Additive Manufacturing ( IF 11.0 ) Pub Date : 2020-09-29 , DOI: 10.1016/j.addma.2020.101625
Laura Cordova , Ton Bor , Marc de Smit , Simone Carmignato , Mónica Campos , Tiedo Tinga

Laser powder-bed fusion (LPBF) technology is one of the additive manufacturing (AM) processes that uses metal powder to produce parts for various industry sectors such as medical, aerospace, automotive and oil&gas. As an ‘additive’ based process, the material is selectively melted by a focused laser. By this working principle material is added in a layer-by-layer approach only where is needed. Therefore, this technology enables a high reduction of waste by avoiding chips typically generated in ‘subtractive’ based processes such as milling and drilling. However, to ensure lower waste consumption the metal powder surrounding the solidified part must be reused in subsequent build jobs. Current knowledge on the effect of powder reuse on LPBF builds is mostly limited to titanium- and nickel- based alloys. The aim of this paper is to study the effect of powder reuse on Al-Mg-Sc-Zr, a high strength aluminium-based alloy, manufactured by LPBF. Here, powder properties such as morphology, composition, particle size distribution are studied of virgin (pristine) and reused Al-Mg-Sc-Zr powder. The mechanical properties of specimens made of virgin powder and after four build cycles are analysed and compared to assess the influence of a mixture of virgin and reused powder material on the consolidated material properties. In general, the powder does not present large differences in composition and morphology, only the reused powder presents coarser particle size distribution (PSD) as previously observed in other alloy compositions. The microstructure of the studied specimens is very similar unlike the porosity. The specimens built with reused powder show a few small micro-sized pores which do not show significant differences in the mechanical properties. In fact, the ultimate tensile strength (UTS) and elongation to break of specimens, respectively built with virgin and reused powder are 565 MPa, 13% and 537 MPa, 11%. Based on the obtained results, it is concluded that it is feasible to reuse Al-Mg-Sc-Zr powder in four subsequent build jobs with proper powder sieving and a rejuvenation step mixing 40% of virgin powder.



中文翻译:

粉末再利用对激光粉末床熔合(LPBF)处理的Al-Mg-Sc-Zr合金显微组织和力学行为的影响

激光粉末床熔合(LPBF)技术是增材制造(AM)工艺之一,该工艺使用金属粉末生产用于医疗,航空航天,汽车和石油和天然气等各个行业的零件。作为基于“添加剂”的过程,材料通过聚焦激光选择性地熔化。通过这种工作原理,仅在需要的地方以逐层方法添加材料。因此,该技术通过避免通常在基于“减法”的工艺(例如铣削和钻孔)中产生的切屑,从而可以大大减少浪费。但是,为确保降低废料消耗,必须将固化部分周围的金属粉末重新用于后续的施工作业。当前关于粉末再利用对LPBF构造的影响的知识主要限于钛和镍基合金。本文的目的是研究粉末再利用对LPBF制造的高强度铝基合金Al-Mg-Sc-Zr的影响。在此,研究了原始(原始)和再利用的Al-Mg-Sc-Zr粉末的粉末性质,如形态,组成,粒度分布。对原始粉末制成的样品的机械性能进行了分析,并比较了四个制造周期后的力学性能,以评估原始粉末和再利用粉末材料的混合物对固结材料性能的影响。通常,粉末在组成和形貌上不会出现较大的差异,只有重新使用的粉末具有较粗的粒度分布(PSD),如先前在其他合金成分中观察到的那样。与孔隙度不同,研究样品的微观结构非常相似。用重复使用的粉末制成的样品显示出一些小的微孔,这些孔的机械性能没有明显差异。实际上,分别由原始粉末和再利用粉末制成的样品的极限抗拉强度(UTS)和断裂伸长率分别为565 MPa(13%)和537 MPa(11%)。根据获得的结果,可以得出结论,在适当的粉末筛分和将40%的原始粉末进行混合的再生步骤中,在随后的四个建造工作中重新使用Al-Mg-Sc-Zr粉末是可行的。

更新日期:2020-09-29
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