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Investigation of Increased Particle Size Distribution for PBF-LB/M Using Ti-6Al-4V
Version 1
: Received: 8 May 2024 / Approved: 9 May 2024 / Online: 13 May 2024 (04:29:03 CEST)
How to cite: Ludwig, I.; Kluge, M. Investigation of Increased Particle Size Distribution for PBF-LB/M Using Ti-6Al-4V. Preprints 2024, 2024050602. https://doi.org/10.20944/preprints202405.0602.v1 Ludwig, I.; Kluge, M. Investigation of Increased Particle Size Distribution for PBF-LB/M Using Ti-6Al-4V. Preprints 2024, 2024050602. https://doi.org/10.20944/preprints202405.0602.v1
Abstract
This study investigates the potential benefits of integrating coarser particle size distributions (PSDs) of 45-106 µm into laser-based powder bed fusion of metals (PBF-LB/M), aiming to reduce costs while maintaining quality standards. Despite the considerable advantages of PBF-LB/M in producing intricate geometries with high precision, the high cost of metal powders remains a barrier to widespread adoption. By exploring the use of coarser PSDs, particularly from electron beam-based powder bed fusion of metals (PBF-EB/M), significant cost-saving opportunities are identified. Through comprehensive powder characterization, process analysis, and mechanical property evaluation, this study demonstrates that PBF-LB/M can effectively utilize coarser powders while achieving comparable mechanical properties to those produced with 20-53 µm PSD. Adaptations in process parameters enable the successful processing of coarser powders, maintaining high-relative density components with minimal porosity. Additionally, market surveys reveal substantial cost differentials between PBF-LB/M and PBF-EB/M powders, indicating 40 % cost reduction potential by integrating coarser PSDs into PBF-LB/M. Overall, this study provides valuable insights into the economic and technical feasibility of printing with coarser powders in PBF-LB/M, offering promising avenues for cost reduction without compromising quality, thus enhancing competitiveness and adoption of the technology in manufacturing applications.
Keywords
PBF-LB/M; Ti-6Al-4V; metal powder; powder blending; increased PSD; flowability, cost reduction
Subject
Engineering, Industrial and Manufacturing Engineering
Copyright: This is an open access article distributed under the Creative Commons Attribution License which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.
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