Scholarlink

<p>This study investigates the optimization of laser powder bed fusion (LPBF) parameters for fabricating support-free 0° overhang structures in stainless steel 316L, with specific application to honeycomb core hollow sandwich structures. Optimal surface energy density (SED) parameters between 1.33 and 2&#xa0;J/mm<sup>2</sup> were identified for the initial overhang layers, achieving &gt; 95% surface coverage without supporting structures. A novel approach involving a&#xa0;gradual increment of volumetric energy density (VED) from 44.44&#xa0;J/mm<sup>3</sup> to 87.96&#xa0;J/mm<sup>3</sup> across six layers was successfully fabricated for support-free overhanging structures. The approach was applied to create honeycomb core sandwich structures with integrated face sheets, eliminating the need for conventional joining methods. Detailed characterization using scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), microhardness testing, and mechanical compression testing confirmed the printed components' structural integrity and mechanical performance. Heat treatment studies at 750&#xa0;°C and 950&#xa0;°C revealed minimal microstructural changes while maintaining structural integrity. Our proposed methodology was scalable, allowing the production of larger honeycomb structures (up to 5 × 5 cells) with consistent quality. Our findings enhance the potential of LPBF for producing complex, lightweight components with minimal post-processing requirements.</p>

错误：搜索内容不能为空，请输入英文关键词
错误：关键词超出字数限制，请精简
高级检索

Optimizing laser powder bed fusion parameters for support-free 0° overhang structures in stainless steel 316L: the case of honeycomb core sandwich structures

  • 期刊论文

  • 发表日期：

    2025年4月10日

查看全文
  • Muslim Al-Mahmood,
  • Wael Abuzaid,
  • Maen Alkhader,
  • Ali S. Alnaser

摘要

This study investigates the optimization of laser powder bed fusion (LPBF) parameters for fabricating support-free 0° overhang structures in stainless steel 316L, with specific application to honeycomb core hollow sandwich structures. Optimal surface energy density (SED) parameters between 1.33 and 2 J/mm2 were identified for the initial overhang layers, achieving > 95% surface coverage without supporting structures. A novel approach involving a gradual increment of volumetric energy density (VED) from 44.44 J/mm3 to 87.96 J/mm3 across six layers was successfully fabricated for support-free overhanging structures. The approach was applied to create honeycomb core sandwich structures with integrated face sheets, eliminating the need for conventional joining methods. Detailed characterization using scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), microhardness testing, and mechanical compression testing confirmed the printed components' structural integrity and mechanical performance. Heat treatment studies at 750 °C and 950 °C revealed minimal microstructural changes while maintaining structural integrity. Our proposed methodology was scalable, allowing the production of larger honeycomb structures (up to 5 × 5 cells) with consistent quality. Our findings enhance the potential of LPBF for producing complex, lightweight components with minimal post-processing requirements.