Get 20M+ Full-Text Papers For Less Than $1.50/day. Start a 14-Day Trial for You or Your Team.

Learn More →

Powder characterization and part density for powder bed fusion of 17-4 PH stainless steel

Powder characterization and part density for powder bed fusion of 17-4 PH stainless steel Characteristics of the metal powder are a key factor in the success of powder bed fusion (PBF) additive manufacturing. Powders for PBF from different manufacturers may have a different particle size and/or bulk packing and flow behavior. Powder properties change as the powder is reused for multiple builds. This study seeks to measure the variability of commercial 17-4 PH stainless steel powders to determine the effect of powder variability on part density and demonstrate characterization methods that ensure part quality.Design/methodology/approachCommercial atomized metal powders from four different vendors were produced with two different atomizing gases (N2 and argon). Powder was characterized in both new and extensively reused conditions. All powders were characterized for flow and packing behavior, particle size and internal porosity. Coupons were manufactured using the laser PBF process with optimized scan strategy and exposure parameters. The quality of fabricated parts was measured using bulk density measurement.FindingsDespite differences in powder flowability and particle size, fully dense parts (>99 per cent) were produced using all powders, except one. Residual porosity in these parts appeared to result from gas trapped in the powder particles. The powder with extensive reuse (400+ h in machine fabrication environment) exhibited reduced flowability and increased fraction of fine particles, but still produced full density parts.Originality/valueThis study demonstrates that full density parts can be fabricated using powders with a range of flowability and packing behavior. This suggests that a single flowability measurement may be sufficient for quality assurance in a production environment. http://www.deepdyve.com/assets/images/DeepDyve-Logo-lg.png Rapid Prototyping Journal Emerald Publishing

Powder characterization and part density for powder bed fusion of 17-4 PH stainless steel

Download PDF
6 pages

Loading next page...
 
/lp/emerald-publishing/powder-characterization-and-part-density-for-powder-bed-fusion-of-17-4-ZTTtj0vWyI
Publisher
Emerald Publishing
Copyright
© Emerald Publishing Limited
ISSN
1355-2546
eISSN
1355-2546
DOI
10.1108/rpj-01-2020-0023
Publisher site
See Article on Publisher Site

Abstract

Characteristics of the metal powder are a key factor in the success of powder bed fusion (PBF) additive manufacturing. Powders for PBF from different manufacturers may have a different particle size and/or bulk packing and flow behavior. Powder properties change as the powder is reused for multiple builds. This study seeks to measure the variability of commercial 17-4 PH stainless steel powders to determine the effect of powder variability on part density and demonstrate characterization methods that ensure part quality.Design/methodology/approachCommercial atomized metal powders from four different vendors were produced with two different atomizing gases (N2 and argon). Powder was characterized in both new and extensively reused conditions. All powders were characterized for flow and packing behavior, particle size and internal porosity. Coupons were manufactured using the laser PBF process with optimized scan strategy and exposure parameters. The quality of fabricated parts was measured using bulk density measurement.FindingsDespite differences in powder flowability and particle size, fully dense parts (>99 per cent) were produced using all powders, except one. Residual porosity in these parts appeared to result from gas trapped in the powder particles. The powder with extensive reuse (400+ h in machine fabrication environment) exhibited reduced flowability and increased fraction of fine particles, but still produced full density parts.Originality/valueThis study demonstrates that full density parts can be fabricated using powders with a range of flowability and packing behavior. This suggests that a single flowability measurement may be sufficient for quality assurance in a production environment.

Journal

Rapid Prototyping Journal – Emerald Publishing

Published: Dec 7, 2020

Keywords: Additive manufacturing; Selective laser melting; 17-4 PH stainless steel; Powder bed fusion; Powder characterization

References

  • Studying the influence of initial powder characteristics on the properties of final parts manufactured by the selective laser melting technology
    Averyanova, M.; Bertrand, P.; Verquin, B.
  • Influence of powder characteristics on processability of AlSi12 alloy fabricated by selective laser melting
    Baitimerov, R.; Lykov, P.; Zherebtsov, D.; Radionova, L.; Shultc, A.; Prashanth, K.G.
  • Morphology and internal structure of porous silicon powders in dependence on the conditions of post-processing
    Belorus, A.O.; Bespalova, K.; , Y.M.; Spivak
  • Characterization of flow properties of powder coatings used in the automotive industry
    Conesa, C.; Saleh, K.; Thomas, A.; Guigon, P.
  • Revealing the effects of powder reuse for selective laser melting by powder characterization
    Cordova, L.; Campos, M.; Tinga, T.
  • Metal additive manufacturing: a review
    Frazier, W.E.
  • Localized changes of stainless steel powder characteristics during selective laser melting additive manufacturing
    Galicki, D.; List, F.; Babu, S.S.; Plotkowski, A.; Meyer, H.M. III; Seals, R.; Hayes, C.
  • Characterization of powder flowability using measurement of angle of repose
    Geldart, D.; Abdullah, E.C.; Hassanpour, A.; Nwokec, L.C.; Wouters, I.
  • Evolution of 316L stainless steel feedstock due to laser powder bed fusion process
    Heiden, M.J.; Deibler, L.A.; Rodelas, J.M.; Koepke, J.R.; Tung, D.J.; Saiz, D.J.; Jared, B.H.
  • Version R2019a:
  • A comprehensive approach to powder feedstock characterization for powder bed fusion additive manufacturing: a case study on AlSi7Mg
    Muñiz-Lerma, J.A.; Nommeots-Nomm, A.; Waters, K.E.; Brochu, M.
  • metallographic testing of powders intended for use in additive manufacturing
    Murphy, T.F.
  • Microstructures and properties of 17-4 PH stainless steel fabricated by selective laser melting
    Murr, L.E.; Martinez, E.; Hernandez, J.; Collins, S.; Amato, K.N.; Gaytan, S.M.; Shindo, P.W.
  • Additive manufacturing (3D printing): a review of materials, methods, applications and challenges
    Ngo, T.D.; Kashani, A.; Imbalzano, G.; Nguyen, K.T.Q.; Hui, D.
  • The strength, fracture toughness, and low cycle fatigue behavior of 17-4 PH stainless steel
    Rack, H.J.; Kalish, D.
  • ImageJ
    Rasband, W.S.
  • 316L Powder Reuse for Metal Additive Manufacturing
    Sartin, B.; Pond, T.; Griffith, B.; Everhart, W.; Elder, L.; Wenski, E.; Cook, C.; Wieliczka, D.; King, W.; Rubenchik, A.; Wu, S.; Brown, B.; Johnson, C.; Crow, J.
  • Characterization of metal powders used for additive manufacturing
    Slotwinski, J.A.; Garboczi, E.J.; Stutzman, P.E.; Ferraris, C.F.; Watson, S.S.; Peltz, M.A.
  • On the development of powder spreadability metrics and feedstock requirements for powder bed fusion additive manufacturing
    Snow, Z.; Martukanitz, R.; Joshi, S.
  • Comparison of density measurement techniques for additive manufactured metallic parts
    Spierings, A.B.
  • Characterization and control of powder properties for additive manufacturing
    Strondl, A.; Lyckfeldt, O.; Brodin, H.; Ackelid, U.
  • Powder characterisation techniques and effects of powder characteristics on part properties in powder-bed fusion processes
    Sutton, A.T.; Kriewall, C.S.; Leu, M.C.; Newkirk, J.W.
  • Recyclability of 304L Stainless Steel in the Selective Laser Melting Process
    Sutton, A.T.; Kriewall, C.S.; Leu, M.C.; Newkirk, J.W.
  • An overview of powder granulometry on feedstock and part performance in the selective laser melting process
    Tan, J.H.; Wong, W.L.E.; Dalgarno, K.W.
  • Powders for powder bed fusion: a review
    Vock, S.; Klöden, B.; Kirchner, A.; Weißgärber, T.; Kieback, B.
  • Effect of powder chemical composition on the as-built microstructure of 17-4 PH stainless steel processed by selective laser melting
    Vunnam, S.; Saboo, A.; Sudbrack, C.; Starr, T.L.
  • Influence of powder bed characteristics on material quality in additive manufacturing
    Zielinski, J.; Vervoort, S.; Mindt, H.-W.; Megahed, M.