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Open AccessArticle
Accelerating Laser Powder Bed Fusion: The Influence of Roller-Spreading Speed on Powder Spreading Performance
by
Mohamed Awad Salim
Mohamed Awad Salim *,
Stephen Tullis
Stephen Tullis and
Mohamed Elbestawi
Mohamed Elbestawi
Department of Mechanical Engineering, McMaster University, Hamilton, ON L8S 4L7, Canada
*
Author to whom correspondence should be addressed.
Metals 2024, 14(10), 1137; https://doi.org/10.3390/met14101137 (registering DOI)
Submission received: 14 August 2024
/
Revised: 30 September 2024
/
Accepted: 3 October 2024
/
Published: 5 October 2024
Abstract
The powder spreading process is a fundamental element within the laser powder bed fusion (PBF-LP) framework given its pivotal role in configuring the powder bed. This configuration significantly influences subsequent processing steps and ultimately determines the quality of the final manufactured part. This research paper presents a comprehensive analysis of the impacts of varying spreading speeds, which are enabled by different roller configurations, on powder distribution in PBF-LP. By utilizing extensive Discrete Element Method (DEM) modelling, we systematically examine how spreading speed affects vital parameters within the spreading process, including packing density, mass fraction, and actual layer thickness. Our exploration of various roller configurations has revealed that increasing spreading speed generally decreases packing density and layer thickness for non-rotating, counter-rotating, and forward-rotating rollers with low clockwise rotational speeds (sub-rolling) due to powder dragging. However, a forward-rotating roller with a high clockwise rotational speed (super-rolling) balances momentum transfer, enhancing packing density and layer thickness while increasing surface roughness. This configuration significantly improves the uniformity and density of the powder bed, providing a technique to accelerate the spreading process while maintaining and not reducing packing density. Furthermore, this configuration offers crucial insights into optimizing additive manufacturing processes by considering the complex relationships between spreading speed, roller configuration, and powder spreading quality.
Share and Cite
MDPI and ACS Style
Salim, M.A.; Tullis, S.; Elbestawi, M.
Accelerating Laser Powder Bed Fusion: The Influence of Roller-Spreading Speed on Powder Spreading Performance. Metals 2024, 14, 1137.
https://doi.org/10.3390/met14101137
AMA Style
Salim MA, Tullis S, Elbestawi M.
Accelerating Laser Powder Bed Fusion: The Influence of Roller-Spreading Speed on Powder Spreading Performance. Metals. 2024; 14(10):1137.
https://doi.org/10.3390/met14101137
Chicago/Turabian Style
Salim, Mohamed Awad, Stephen Tullis, and Mohamed Elbestawi.
2024. "Accelerating Laser Powder Bed Fusion: The Influence of Roller-Spreading Speed on Powder Spreading Performance" Metals 14, no. 10: 1137.
https://doi.org/10.3390/met14101137
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