Experimental and numerical investigation of the origin of surface roughness in laser powder bed fused overhang regions

Shaochuan Feng*, Amar M. Kamat, Soheil Sabooni, Yutao T. Pei

*Bijbehorende auteur voor dit werk

OnderzoeksoutputAcademicpeer review

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Surface roughness of laser powder bed fusion (L-PBF) printed overhang regions is a major contributor to deteriorated shape accuracy/surface quality. This study investigates the mechanisms behind the evolution of surface roughness (Ra) in overhang regions. The evolution of surface morphology is the result of a combination of border track contour, powder adhesion, warp deformation, and dross formation, which is strongly related to the overhang angle (θ). When 0° ≤ θ ≤ 15°, the overhang angle does not affect Ra significantly since only a small area of the melt pool boundaries contacts the powder bed resulting in slight powder adhesion. When 15° < θ ≤ 50°, powder adhesion is enhanced by the melt pool sinking and the increased contact area between the melt pool boundary and powder bed. When θ > 50°, large waviness of the overhang contour, adhesion of powder clusters, severe warp deformation and dross formation increase Ra sharply.
Originele taal-2English
Pagina's (van-tot)S66-S84
Aantal pagina's19
TijdschriftVirtual and Physical Prototyping
Nummer van het tijdschriftsup. 1
Vroegere onlinedatum10-mrt-2021
StatusPublished - 2021

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