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Title: Predicting mechanical property plateau in laser polymer powder bed fusion additive manufacturing via the critical coalescence ratio

Abstract

The state of the art in property-process relationships in the laser polymer powder bed fusion (LPPBF) subcategory of powder bed fusion (PBF) has derived relationships between the energy supplied and polymer thermal properties governing melting and degradation, so-called the “energy melt ratio (EMR).” The EMR provides a framework for process parameter value selection based solely on melting behavior. However, coalescence, and not merely melting, is the basis for mechanical properties in LPPBF printed parts. The authors present a method for (1) predicting polymer coalescence based on transient temperature profiles resulting from a combination of LPPBF process parameter values and (2) connecting the predicted coalescence response to the observed onset of a plateau in mechanical properties. This work tests the hypothesis that the observed onset of a mechanical property plateau corresponds with a transition in consolidation physics. Complete coalescence must be achieved prior to the onset of physical gelation. For this work, in situ transient temperature profiles were obtained using infrared thermography. Coalescence prediction, via the Upper-convected Maxwell model, and physical gelation prediction, via Lauritzen-Hoffman and Avrami equations, were found to successfully identify LPPBF parameter combinations resulting in parts with density and tensile strength inside the plateau region. The hypothesis thatmore » the plateau occurs at the onset of closed pore morphology is supported.« less

Authors:
; ; ; ;
Publication Date:
Research Org.:
Kansas City Plant (KCP), Kansas City, MO (United States)
Sponsoring Org.:
USDOE National Nuclear Security Administration (NNSA)
OSTI Identifier:
1761271
Alternate Identifier(s):
OSTI ID: 1666366
Report Number(s):
NSC-614-3142
Journal ID: ISSN 0264-1275; S0264127521000277; 109474; PII: S0264127521000277
Grant/Contract Number:  
NA0002839
Resource Type:
Published Article
Journal Name:
Materials & Design
Additional Journal Information:
Journal Name: Materials & Design Journal Volume: 201 Journal Issue: C; Journal ID: ISSN 0264-1275
Publisher:
Elsevier
Country of Publication:
United Kingdom
Language:
English
Subject:
36 MATERIALS SCIENCE; additive manufacturing; powder bed fusion; selective laser sintering; polymer coalescence; process parameter prediction; physical gelation

Citation Formats

Chatham, Camden A., Bortner, Michael J., Johnson, Blake N., Long, Timothy E., and Williams, Christopher B. Predicting mechanical property plateau in laser polymer powder bed fusion additive manufacturing via the critical coalescence ratio. United Kingdom: N. p., 2021. Web. doi:10.1016/j.matdes.2021.109474.
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Chatham, Camden A., Bortner, Michael J., Johnson, Blake N., Long, Timothy E., & Williams, Christopher B. Predicting mechanical property plateau in laser polymer powder bed fusion additive manufacturing via the critical coalescence ratio. United Kingdom. https://doi.org/10.1016/j.matdes.2021.109474
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Chatham, Camden A., Bortner, Michael J., Johnson, Blake N., Long, Timothy E., and Williams, Christopher B. Mon . "Predicting mechanical property plateau in laser polymer powder bed fusion additive manufacturing via the critical coalescence ratio". United Kingdom. https://doi.org/10.1016/j.matdes.2021.109474.
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@article{osti_1761271,
title = {Predicting mechanical property plateau in laser polymer powder bed fusion additive manufacturing via the critical coalescence ratio},
author = {Chatham, Camden A. and Bortner, Michael J. and Johnson, Blake N. and Long, Timothy E. and Williams, Christopher B.},
abstractNote = {The state of the art in property-process relationships in the laser polymer powder bed fusion (LPPBF) subcategory of powder bed fusion (PBF) has derived relationships between the energy supplied and polymer thermal properties governing melting and degradation, so-called the “energy melt ratio (EMR).” The EMR provides a framework for process parameter value selection based solely on melting behavior. However, coalescence, and not merely melting, is the basis for mechanical properties in LPPBF printed parts. The authors present a method for (1) predicting polymer coalescence based on transient temperature profiles resulting from a combination of LPPBF process parameter values and (2) connecting the predicted coalescence response to the observed onset of a plateau in mechanical properties. This work tests the hypothesis that the observed onset of a mechanical property plateau corresponds with a transition in consolidation physics. Complete coalescence must be achieved prior to the onset of physical gelation. For this work, in situ transient temperature profiles were obtained using infrared thermography. Coalescence prediction, via the Upper-convected Maxwell model, and physical gelation prediction, via Lauritzen-Hoffman and Avrami equations, were found to successfully identify LPPBF parameter combinations resulting in parts with density and tensile strength inside the plateau region. The hypothesis that the plateau occurs at the onset of closed pore morphology is supported.},
doi = {10.1016/j.matdes.2021.109474},
journal = {Materials & Design},
number = C,
volume = 201,
place = {United Kingdom},
year = {Mon Mar 01 00:00:00 EST 2021},
month = {Mon Mar 01 00:00:00 EST 2021}
}
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https://doi.org/10.1016/j.matdes.2021.109474
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