Framework to Accelerate Parameter Development for Laser Powder Bed Fusion

Metal Laser Powder Bed Fusion (M-LPBF) is a method of additive manufacturing that enables the fabrication of complex components that would not be possible through conventional manufacturing methods. M-LPBF is well suited for aerospace applications not only because of its ability to fabricate complex and efficient components, but it also can enable the reduction of cost and the schedule of programs. The recent advancements in material development could open the design space even further for aerospace applications, but the initial development process of evaluating a new material on a M-LPBF printer can be time consuming and costly. In this work, a framework to improve the efficiency and structure of M-LPBF process development is proposed. First, simulations of the melt pool were performed to understand the impact of primary process parameters on the dimensions of the melt pool. Then, tools to model the melt pool were tested and used in combination with analytical equations to identify an acceptable processing window for the M-LPBF process. Following this process parameter filtering, physical experiments were executed that investigated the impact of process and design parameters on various outputs connected to the melt pool, density, dimensional accuracy, and surface roughness of the coupons printed. Optimal parameter ranges can then be determined according to different design and process priorities. The framework developed in this project enables a material and machine agnostic approach to process parameter selection in less time and at a lower cost.

Name thesis:degree_name

Master

Department dc:contributor.department

Massachusetts Institute of Technology. Department of Mechanical Engineering

Grantor dc:publisher

Massachusetts Institute of Technology

Year dc:date.issued

2022

Author dc:creator

• Graybill, Benjamin C.

Advisors dc:contributor.advisor

• Hardt, David
• Hart, John

Statement dc:rights

• In Copyright - Educational Use Permitted
• Copyright retained by author(s)

Licence dc:rights.uri

• https://rightsstatements.org/page/InC-EDU/1.0/

Handle dc:identifier.uri

https://hdl.handle.net/1721.1/147520

OAI identifier oai:identifier

oai:dspace.mit.edu:1721.1/147520