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author:

Wang, Feihong (Wang, Feihong.) [1] | Wu, Chaochao (Wu, Chaochao.) [2] (Scholars:吴潮潮) | Liang, Yongfeng (Liang, Yongfeng.) [3] | Liang, Xiaoyu (Liang, Xiaoyu.) [4] | Wu, Honghui (Wu, Honghui.) [5] | Liu, Li (Liu, Li.) [6] | Lin, Feng (Lin, Feng.) [7] | Kan, Wenbin (Kan, Wenbin.) [8] | Lin, Junpin (Lin, Junpin.) [9]

Indexed by:

EI Scopus SCIE

Abstract:

Electron beam powder bed fusion (EB-PBF) is a key metal additive manufacturing (AM) technology known for its high energy absorption and low heat stress. However, the high surface roughness of EB-PBF parts has limited its broader application. To address this issue, this paper proposes a dashed-scan contouring strategy to obtain lower surface roughness in EB-PBF. This strategy involves melting the contour in the form of segmented staggered scans and employing high-frequency jumping of the electron beam (EB) to melt multiple positions synchronously. A comprehensive analysis, combining experimental investigations and multi-physical simulations, elucidates the intrinsic connection between control processes and melt pool stability. Results show that by controlling the length-to-width ratio of the melt pool, regulating overlap distances between melt pools, and fine-tuning cooling times, balling phenomena and Plateau-Rayleigh instabilities can be suppressed. Additionally, these measures effectively mitigate irregularities in track formation when compared to the traditional process. Experimental validation demonstrates the efficacy of the approach, achieving reduced surface roughness (Ra) of thin-walled Ti6Al-4 V parts from over 25 mu m to below 12.6 mu m, while enhancing dimensional accuracy and reducing melt anomalies at corners. The proposed dashed-scan contouring strategy opens new avenues for AM of highly reliable and intricate structures, such as lattice sandwich structures, thin walls, and internal flow passages.

Keyword:

Contouring strategy Electron beam melting Melt pool Multi-physical simulation Powder bed fusion Surface quality

Community:

  • [ 1 ] [Wang, Feihong]Univ Sci & Technol Beijing, State Key Lab Adv Met & Mat, Beijing 100083, Peoples R China
  • [ 2 ] [Liang, Yongfeng]Univ Sci & Technol Beijing, State Key Lab Adv Met & Mat, Beijing 100083, Peoples R China
  • [ 3 ] [Wu, Honghui]Univ Sci & Technol Beijing, State Key Lab Adv Met & Mat, Beijing 100083, Peoples R China
  • [ 4 ] [Lin, Junpin]Univ Sci & Technol Beijing, State Key Lab Adv Met & Mat, Beijing 100083, Peoples R China
  • [ 5 ] [Wu, Chaochao]Fuzhou Univ, Sch Mech Engn & Automat, Fuzhou 350108, Peoples R China
  • [ 6 ] [Liu, Li]Beijing Quick Beam Technol Co Ltd, Beijing 100176, Peoples R China
  • [ 7 ] [Kan, Wenbin]Beijing Quick Beam Technol Co Ltd, Beijing 100176, Peoples R China
  • [ 8 ] [Liang, Xiaoyu]Tsinghua Univ, Dept Mech Engn, State Key Lab Clean & Efficient Turbomachinery Pow, Beijing 100084, Peoples R China
  • [ 9 ] [Lin, Feng]Tsinghua Univ, Dept Mech Engn, State Key Lab Clean & Efficient Turbomachinery Pow, Beijing 100084, Peoples R China
  • [ 10 ] [Liang, Xiaoyu]Minist Educ, Key Lab Adv Mat Proc Technol, Beijing 100084, Peoples R China
  • [ 11 ] [Lin, Feng]Minist Educ, Key Lab Adv Mat Proc Technol, Beijing 100084, Peoples R China

Reprint 's Address:

  • [Lin, Junpin]Univ Sci & Technol Beijing, State Key Lab Adv Met & Mat, Beijing 100083, Peoples R China;;[Lin, Feng]Tsinghua Univ, Dept Mech Engn, State Key Lab Clean & Efficient Turbomachinery Pow, Beijing 100084, Peoples R China;;

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Source :

JOURNAL OF MATERIALS PROCESSING TECHNOLOGY

ISSN: 0924-0136

Year: 2024

Volume: 330

6 . 7 0 0

JCR@2023

CAS Journal Grade:2

Cited Count:

WoS CC Cited Count: 1

SCOPUS Cited Count: 1

ESI Highly Cited Papers on the List: 0 Unfold All

WanFang Cited Count:

Chinese Cited Count:

30 Days PV: 0

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