Process Study of Selective Laser Sintering of PS/GF/HGM Composites
Abstract
:1. Introduction
2. The Experimental Section
2.1. Experimental Material and Equipment
2.2. Preparation of PS/GF/HGM Composite Powder
2.3. Preparation of Sample
2.4. Performance Testing and Characterization
3. Results
4. Discussion
4.1. Analysis of Bending Strength Variance
4.2. Precision Analysis of Variance
4.3. Determine the Best Process Parameter Combination
4.4. Microstructure of Sintered Parts
5. Conclusions
- (1)
- Referring to bending strength as the index, the degree of influence of process parameters on PS/GF/HGM composites’ bending strength ranks from highest to lowest as scanning spacing, scanning speed, laser power, and delamination thickness. The optimal combination of process parameters is a laser power of 33 W, scanning speed of 1600mm/s, scanning spacing of 0.15 mm, and delamination thickness of 0.16 mm. At this point in time, sintered parts can achieve a bending strength of 12.06 MPa.
- (2)
- The influence of process parameters on the relative error of Z-dimension in PS/GF/HGM composites, as measured by accuracy, follows the order of scanning spacing, delamination thickness, laser power, and scanning speed. The optimal process parameters for achieving a minimal relative error in the Z-direction size of sintered parts are as follows: laser power at 24 W, scanning speed at 2200 mm/s, scanning spacing at 0.24 mm, and delamination thickness at 0.22 mm. Consequently, the resulting relative error of Z-direction dimensions of sintered parts is −0.67% at this time.
- (3)
- After evaluating the strength and precision of the PS/GF/HGM composite sintered component within the experimental range, the optimal process parameter combination for this part is a laser power of 24 W, scanning speed of 1600 mm/s, scanning spacing of 0.24 mm, and delamination thickness of 0.22 mm. Under these process conditions, the sintered parts exhibit a bending strength of 6.12 MPa and a relative error of Z-dimension at 0.87%, which is 15.69% higher than that of pure polystyrene powder sintered parts, while reducing the relative error by 63.45%.
Author Contributions
Funding
Institutional Review Board Statement
Informed Consent Statement
Data Availability Statement
Conflicts of Interest
References
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Level | Experimental Factor | |||
---|---|---|---|---|
Laser Power (A)/W | Scanning Speed | Scanning Spacing (C)/mm | Delamination Thickness (D)/mm | |
1 | 24 | 1600 | 0.15 | 0.16 |
2 | 27 | 1800 | 0.18 | 0.18 |
3 | 30 | 2000 | 0.21 | 0.20 |
4 | 33 | 2200 | 0.21 | 0.22 |
Group Number | Experimental Factor | Experimental Result | ||||
---|---|---|---|---|---|---|
A/W | C/mm | D/mm | Z-Dimensional Relative Error/% | Bending Strength/MPa | ||
1 | 24 | 1600 | 0.15 | 0.16 | 7.93 | 12.06 |
2 | 24 | 1800 | 0.18 | 0.18 | 2.41 | 7.92 |
3 | 24 | 2000 | 0.21 | 0.20 | 1.06 | 5.20 |
4 | 24 | 2200 | 0.24 | 0.22 | −0.67 | 3.65 |
5 | 27 | 1600 | 0.18 | 0.20 | 4.02 | 9.28 |
6 | 27 | 1800 | 0.15 | 0.22 | 5.98 | 9.84 |
7 | 27 | 2000 | 0.24 | 0.16 | 1.66 | 5.23 |
8 | 27 | 2200 | 0.21 | 0.18 | 2.45 | 5.11 |
9 | 30 | 1600 | 0.21 | 0.22 | 2.17 | 7.80 |
10 | 30 | 1800 | 0.24 | 0.20 | 1.82 | 6.47 |
11 | 30 | 2000 | 0.15 | 0.18 | 7.46 | 10.37 |
12 | 30 | 2200 | 0.18 | 0.16 | 5.53 | 8.43 |
13 | 33 | 1600 | 0.24 | 0.18 | 3.28 | 7.99 |
14 | 33 | 1800 | 0.21 | 0.16 | 5.12 | 8.96 |
15 | 33 | 2000 | 0.18 | 0.22 | 3.84 | 7.88 |
16 | 33 | 2200 | 0.15 | 0.20 | 6.59 | 9.78 |
Calculated Value | Experimental Factor | |||
---|---|---|---|---|
A | B | C | D | |
M1 | 28.83 | 37.13 | 42.08 | 34.68 |
M2 | 29.49 | 33.22 | 33.51 | 31.39 |
M3 | 33.07 | 28.68 | 27.07 | 30.73 |
M4 | 34.61 | 26.97 | 23.34 | 29.20 |
m1 | 7.2075 | 9.2825 | 10.52 | 8.67 |
m2 | 7.3725 | 8.305 | 8.3775 | 7.8475 |
m3 | 8.2625 | 7.17 | 6.7675 | 7.6825 |
m4 | 8.6525 | 6.7425 | 5.835 | 7.30 |
Rj | 1.445 | 2.54 | 4.685 | 1.37 |
Sj | 5.82650 | 15.78215 | 50.54675 | 4.00185 |
Prioritization Scheme | A4 | B1 | C1 | D1 |
Variance Factor | Variance | Degree of Freedom | Average Variance | Error Ratio | Significance Level |
---|---|---|---|---|---|
A | 5.8265 | 3 | 1.942167 | 19.902647 | ** |
B | 15.78215 | 3 | 5.260717 | 53.909991 | *** |
C | 50.54675 | 3 | 16.848917 | 172.661828 | **** |
D | 4.00185 | 3 | 1.33395 | 13.669855 | * |
Error Value | 0.29275 | 3 | 0.097583 | ||
Total | 76.45 | 15 |
Calculated Value | Experimental Factor | |||
---|---|---|---|---|
A | B | C | D | |
M1 | 10.73 | 17.4 | 27.96 | 20.24 |
M2 | 14.11 | 15.33 | 15.8 | 15.06 |
M3 | 16.98 | 14.02 | 10.8 | 13.49 |
M4 | 18.83 | 13.9 | 6.09 | 11.32 |
m1 | 2.6825 | 4.35 | 6.99 | 5.06 |
m2 | 3.5275 | 3.8325 | 3.95 | 3.9 |
m3 | 4.245 | 3.505 | 2.7 | 3.3725 |
m4 | 4.7075 | 3.475 | 1.5225 | 2.83 |
Rj | 2.025 | 0.875 | 5.4675 | 2.23 |
Sj | 9.377169 | 1.983419 | 66.381019 | 10.883619 |
Prioritization Scheme | A1 | B4 | C4 | D4 |
Variance Factor | Variance | Degree of Freedom | Average Variance | Error Ratio | Significance Level |
---|---|---|---|---|---|
A | 9.377169 | 3 | 3.125723 | 5.157763 | ** |
B | 1.983419 | 3 | 0.661140 | 1.090949 | * |
C | 66.381019 | 3 | 22.127006 | 36.511825 | **** |
D | 10.883619 | 3 | 3.627873 | 5.986362 | *** |
Error Value | 1.818069 | 3 | 0.606023 | ||
Total | 90.443295 | 15 |
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Liu, L.; Zhu, S.; Zhang, Y.; Ma, S.; Wu, S.; Wei, B.; Yang, G. Process Study of Selective Laser Sintering of PS/GF/HGM Composites. Materials 2024, 17, 1066. https://doi.org/10.3390/ma17051066
Liu L, Zhu S, Zhang Y, Ma S, Wu S, Wei B, Yang G. Process Study of Selective Laser Sintering of PS/GF/HGM Composites. Materials. 2024; 17(5):1066. https://doi.org/10.3390/ma17051066
Chicago/Turabian StyleLiu, Lijian, Shouxiao Zhu, Yongkang Zhang, Shaobo Ma, Shuxuan Wu, Bin Wei, and Guang Yang. 2024. "Process Study of Selective Laser Sintering of PS/GF/HGM Composites" Materials 17, no. 5: 1066. https://doi.org/10.3390/ma17051066