Impact of powder reusability on batch repeatability of Ti6Al4V ELI for PBF-LB industrial production

Laura Cordova; Cindy Sithole; Eric Macía Rodríguez; Ian Gibson; Mónica Campos

doi:10.1080/00325899.2022.2133357

Impact of powder reusability on batch repeatability of Ti6Al4V ELI for PBF-LB industrial production

Laura Cordova^*
, Cindy Sithole
, Eric Macía Rodríguez
, Ian Gibson
, Mónica Campos

^*Corresponding author for this work

Research output: Contribution to journal › Article › Academic › peer-review

11 Citations (Scopus)

223 Downloads (Pure)

Abstract

In powder bed fusion laser beam (PBF-LB), powder reusability remains key to keeping cost-effectivity as well as sustainability. In this study, highly sensitive Ti6Al4V ELI powder typically used for medical and aerospace applications is studied. Powder properties of new and reused powders after 10 build cycles subjected to variations such as morphology, particle size distribution (PSD), chemical composition and flowability were analysed. The flow rate using Carney flowmeter increased from 6.8 s to 12 s. Oxygen content slightly increased from 0.11% to 0.12%. The dimensional deviations are measured in six builds of eight samples spread through the build plate. The density of the cubes does not show relevant differences in density (from 99.6% to 99.9%), only the last batch exhibits slightly lower density than the previous builds. Studied properties for the powder and builds are maintained throughout the experiment, demonstrating repeatability of industrial production of metal parts.

Original language	English
Pages (from-to)	129-138
Number of pages	10
Journal	Powder Metallurgy
Volume	66
Issue number	2
Early online date	18 Oct 2022
DOIs	https://doi.org/10.1080/00325899.2022.2133357
Publication status	Published - 2023

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

SDG 9 Industry, Innovation, and Infrastructure

Keywords

UT-Hybrid-D
Grade 23
Industrial AM
Powder bed fusion laser beam (PBF-LB)
Powder reusability
Repeatability
Ti6Al4V ELI
Batch production

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10.1080/00325899.2022.2133357Licence: CC BY-NC-ND

ArticleFinal published version, 2.94 MBLicence: CC BY-NC-ND

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title = "Impact of powder reusability on batch repeatability of Ti6Al4V ELI for PBF-LB industrial production",

abstract = "In powder bed fusion laser beam (PBF-LB), powder reusability remains key to keeping cost-effectivity as well as sustainability. In this study, highly sensitive Ti6Al4V ELI powder typically used for medical and aerospace applications is studied. Powder properties of new and reused powders after 10 build cycles subjected to variations such as morphology, particle size distribution (PSD), chemical composition and flowability were analysed. The flow rate using Carney flowmeter increased from 6.8 s to 12 s. Oxygen content slightly increased from 0.11\% to 0.12\%. The dimensional deviations are measured in six builds of eight samples spread through the build plate. The density of the cubes does not show relevant differences in density (from 99.6\% to 99.9\%), only the last batch exhibits slightly lower density than the previous builds. Studied properties for the powder and builds are maintained throughout the experiment, demonstrating repeatability of industrial production of metal parts.",

keywords = "UT-Hybrid-D, Grade 23, Industrial AM, Powder bed fusion laser beam (PBF-LB), Powder reusability, Repeatability, Ti6Al4V ELI, Batch production",

author = "Laura Cordova and Cindy Sithole and \{Mac{\'i}a Rodr{\'i}guez\}, Eric and Ian Gibson and M{\'o}nica Campos",

note = "Funding Information: This work was supported by National Research Foundation of South Africa [grant number 120210]; Nederlandse Organisatie Voor Wetenschappelijk Onderzoek. This research has been supported by the Dutch Research Council (NWO) with the TKI{\textendash}Connecting industry program under the project {\textquoteleft}Development of flexible and integrated additive manufacturing systems{\textquoteright}. The authors are grateful to Sandra Poelsma from Additive Industries for her support with machine operation. Funding Information: This research has been supported by the Dutch Research Council (NWO) with the TKI {\textendash} Connecting industry program under the project {\textquoteleft}Development of flexible and integrated additive manufacturing systems{\textquoteright}. The authors are grateful to Sandra Poelsma from Additive Industries for her support with machine operation. Publisher Copyright: {\textcopyright} 2022 The Author(s). Published by Informa UK Limited, trading as Taylor \& Francis Group.",

year = "2023",

doi = "10.1080/00325899.2022.2133357",

language = "English",

volume = "66",

pages = "129--138",

journal = "Powder Metallurgy",

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publisher = "Sage",

number = "2",

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T1 - Impact of powder reusability on batch repeatability of Ti6Al4V ELI for PBF-LB industrial production

AU - Cordova, Laura

AU - Sithole, Cindy

AU - Macía Rodríguez, Eric

AU - Gibson, Ian

AU - Campos, Mónica

N1 - Funding Information: This work was supported by National Research Foundation of South Africa [grant number 120210]; Nederlandse Organisatie Voor Wetenschappelijk Onderzoek. This research has been supported by the Dutch Research Council (NWO) with the TKI–Connecting industry program under the project ‘Development of flexible and integrated additive manufacturing systems’. The authors are grateful to Sandra Poelsma from Additive Industries for her support with machine operation. Funding Information: This research has been supported by the Dutch Research Council (NWO) with the TKI – Connecting industry program under the project ‘Development of flexible and integrated additive manufacturing systems’. The authors are grateful to Sandra Poelsma from Additive Industries for her support with machine operation. Publisher Copyright: © 2022 The Author(s). Published by Informa UK Limited, trading as Taylor & Francis Group.

PY - 2023

Y1 - 2023

N2 - In powder bed fusion laser beam (PBF-LB), powder reusability remains key to keeping cost-effectivity as well as sustainability. In this study, highly sensitive Ti6Al4V ELI powder typically used for medical and aerospace applications is studied. Powder properties of new and reused powders after 10 build cycles subjected to variations such as morphology, particle size distribution (PSD), chemical composition and flowability were analysed. The flow rate using Carney flowmeter increased from 6.8 s to 12 s. Oxygen content slightly increased from 0.11% to 0.12%. The dimensional deviations are measured in six builds of eight samples spread through the build plate. The density of the cubes does not show relevant differences in density (from 99.6% to 99.9%), only the last batch exhibits slightly lower density than the previous builds. Studied properties for the powder and builds are maintained throughout the experiment, demonstrating repeatability of industrial production of metal parts.

AB - In powder bed fusion laser beam (PBF-LB), powder reusability remains key to keeping cost-effectivity as well as sustainability. In this study, highly sensitive Ti6Al4V ELI powder typically used for medical and aerospace applications is studied. Powder properties of new and reused powders after 10 build cycles subjected to variations such as morphology, particle size distribution (PSD), chemical composition and flowability were analysed. The flow rate using Carney flowmeter increased from 6.8 s to 12 s. Oxygen content slightly increased from 0.11% to 0.12%. The dimensional deviations are measured in six builds of eight samples spread through the build plate. The density of the cubes does not show relevant differences in density (from 99.6% to 99.9%), only the last batch exhibits slightly lower density than the previous builds. Studied properties for the powder and builds are maintained throughout the experiment, demonstrating repeatability of industrial production of metal parts.

KW - UT-Hybrid-D

KW - Grade 23

KW - Industrial AM

KW - Powder bed fusion laser beam (PBF-LB)

KW - Powder reusability

KW - Repeatability

KW - Ti6Al4V ELI

KW - Batch production

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DO - 10.1080/00325899.2022.2133357

M3 - Article

AN - SCOPUS:85140127436

SN - 0032-5899

VL - 66

SP - 129

EP - 138

JO - Powder Metallurgy

JF - Powder Metallurgy

IS - 2

ER -

Impact of powder reusability on batch repeatability of Ti6Al4V ELI for PBF-LB industrial production

Abstract

UN SDGs

Keywords

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QUALITY STRATEGY FOR METAL ADDITIVE MANUFACTURING: A STRATEGY BASED ON QUALITY BY DESIGN AND DESIGN FOR SIX SIGMA FOR BATCH PRODUCTION IN METAL LASER POWDER BED FUSION TECHNOLOGY

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