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<p>Laser powder bed fusion (LPBF) is used to manufacture complex, thin-walled components with arc surfaces. However, the degradation of the quality of overhang surfaces significantly limits its engineering applications. This study investigates how contour parameters influence overhang surface roughness, using Inconel 718 as the material. A Taguchi experimental design was employed in conjunction with a main-effect analysis of the signal-to-noise (S/N) ratio to optimize processing parameters. Scanning electron microscopy (SEM) was used to characterize the surface micro-morphology of thin-walled structures. The results demonstrate that a concurrent reduction in both laser power and scanning speed effectively suppresses dross formation on the overhang surface. Furthermore, implementing laser in-situ remelting significantly reduces surface defects such as adhering powder particles, spheroidization, and lack of fusion. This parameter modulation strategy, implemented without altering hatch parameters, markedly reduces the post-processing requirements for overhang surfaces of arc surface, thin-walled components. The findings clarify the formation mechanisms of surface defects that are influenced by contour parameters. This provides a technological basis for the rapid production of complex, high-performance hollow closure structures.</p>

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Effect of Contour Processing and In Situ Laser Remelting on the Overhanging Region Surface Morphology of Thin-Walled Inconel 718 Structures Fabricated by Laser Powder Bed Fusion

  • 期刊论文

  • 发表日期：

    2025年10月30日

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  • Yuancai Li,
  • Deqiao Xie,
  • Weiping Deng,
  • Zongjun Tian,
  • Jianfeng Zhao,
  • Guidian Ma,
  • Zhaoyang Song

摘要

Laser powder bed fusion (LPBF) is used to manufacture complex, thin-walled components with arc surfaces. However, the degradation of the quality of overhang surfaces significantly limits its engineering applications. This study investigates how contour parameters influence overhang surface roughness, using Inconel 718 as the material. A Taguchi experimental design was employed in conjunction with a main-effect analysis of the signal-to-noise (S/N) ratio to optimize processing parameters. Scanning electron microscopy (SEM) was used to characterize the surface micro-morphology of thin-walled structures. The results demonstrate that a concurrent reduction in both laser power and scanning speed effectively suppresses dross formation on the overhang surface. Furthermore, implementing laser in-situ remelting significantly reduces surface defects such as adhering powder particles, spheroidization, and lack of fusion. This parameter modulation strategy, implemented without altering hatch parameters, markedly reduces the post-processing requirements for overhang surfaces of arc surface, thin-walled components. The findings clarify the formation mechanisms of surface defects that are influenced by contour parameters. This provides a technological basis for the rapid production of complex, high-performance hollow closure structures.