Laser Powder Bed Fusion

Sponsors: Kansas City National Security Campus, Clean Energy Smart Manufacturing Innovation Institute

 

Description

Laser Powder-Bed Fusion (L-PBF), also called Selective Laser Melting, directs a laser beam to selectively fuse powder in each layer into a complex geometry with little porosity. Inconsistencies in part properties that may result have motivated researchers to study the sources of variation in part properties for quality control purposes. A critical source of variation is the feedstock, where batch-to-batch differences and changes in the powder characteristics with reuse affect part properties. During the L-PBF process, laser spatter and condensate form and deposit in the powder bed surrounding the built parts. These particulates (known as ejecta) differ morphologically and chemically from the virgin powder, potentially compromising the reusability of powder for the next builds. 
  1. “Evolution of AISI 304L Stainless Steel Part Properties due to Powder Recycling in Laser Powder-Bed Fusion,” A. T. Sutton, C. S. Kriewall, S. Karnati, M. C. Leu, and J. W. Newkirk, Additive Manufacturing, Vol. 36, Dec. 2020. 
  2. “Characterization of Laser Spatter and Condensate Generated during the Selective Laser Melting of 304L Stainless Steel Powder,” A. T. Sutton, C. S. Kriewall, M. C. Leu, J. W. Newkirk, and B. Brown, Additive Manufacturing, Vol. 31, Jan. 2020 (15 pages)
  3. Powder Characterization Techniques and Effects of Powder Characteristics on Part Properties in Powder-Bed Based Additive Manufacturing: A Review,” A. T. Sutton, C. S. Kriewall, M. C. Leu and J. W. Newkirk, Journal of Virtual and Physical Prototyping, Vol. 12, No. 1, 2017, pp. 3-29.
  4. “Effects of Area Fraction and Part Spacing on Degradation of 304L Stainless Steel Powder in Selective Laser Melting,” C. Kriewall, A. Sutton, S. Karnati, M. C. Leu, and J. Newkirk N., Proceedings of Solid Freeform Fabrication Symposium, Austin, TX, Aug. 7-9, 2017.