High density net shape components by direct laser re-melting of single-phase powders |
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Authors: | R H Morgan A J Papworth C Sutcliffe P Fox W O'neill |
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Affiliation: | (1) Department of Engineering (Manufacturing), The University of Liverpool, Liverpool, L69 3GH, UK |
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Abstract: | Direct Metal Laser Re-Melting is a variant of the Selective Laser Sintering process, a Rapid Prototyping (RP) technology. This tool-less manufacturing technology has the potential of producing complex, high quality components from single-phase metal powders in short time scales. This is made possible by the production of consecutive two-dimensional layers. Unfortunately, finished components manufactured by this technique have their integrity and material properties dictated by the porosity within the laser re-melted structure. In order to maintain structural integrity comparable to conventionally produced components, metal components produced by the rapid prototyping method should exhibit a porosity of the order of maximum of 2% with corresponding bulk material properties. To achieve these objectives, process and laser parameters require optimisation for maximum densities to be attained. This paper reports on the development of a scanning strategy that produces stainless steel (316L) laser re-melted components which exhibit porosities of <1%, while maintaining the concept of rapid prototyping. |
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