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Investigation of Mg evaporation on LPBF process robustness
Laser powder bed fusion (LPBF) of metals is a process where three dimensional parts are manufactured by sequentially spreading thin layers of metal powder feedstock and melting portions with a laser. Byproducts of the process, such as fume and spatter, originated by the dynamics of the melt pool, can fall onto the powder bed or interact with the laser and potentially cause material defects in the parts. In this project, the student will conduct experimental builds and investigate to what extend the byproducts generation impact on the process robustness.
Powder bed additive manufacturing processes selectively fuse together many thin two-dimensional layers to create three-dimensional parts. By doing this a laser beam moves along a predefined pattern melting the powder, the molten material forms the so-called melt pool, where extremely high temperatures are reached, causing the vaporization of alloying elements owing a high vapor pressure (e.g. Mg). This leads to the formation of fume and spatter, besides a depletion in Mg content which can causes unevenness in chemical composition and parts properties.
Despite Mg is widely used as strengthener in Al alloys, the development of Mg-free alloys is expected to bring several advantages including a more robust processability compared to Mg-containing alloys.
In the Advanced Manufacturing Lab at ETH Zurich (am|z) and at inspire icams (innovation center for additive manufacturing Switzerland), we are conducting research on additively manufactured aluminum alloys developing a Mg-free alloy specifically designed for LPBF that aims to compete with some more common Al alloys currently available on the market.
Powder bed additive manufacturing processes selectively fuse together many thin two-dimensional layers to create three-dimensional parts. By doing this a laser beam moves along a predefined pattern melting the powder, the molten material forms the so-called melt pool, where extremely high temperatures are reached, causing the vaporization of alloying elements owing a high vapor pressure (e.g. Mg). This leads to the formation of fume and spatter, besides a depletion in Mg content which can causes unevenness in chemical composition and parts properties. Despite Mg is widely used as strengthener in Al alloys, the development of Mg-free alloys is expected to bring several advantages including a more robust processability compared to Mg-containing alloys. In the Advanced Manufacturing Lab at ETH Zurich (am|z) and at inspire icams (innovation center for additive manufacturing Switzerland), we are conducting research on additively manufactured aluminum alloys developing a Mg-free alloy specifically designed for LPBF that aims to compete with some more common Al alloys currently available on the market.
In this project, our aim is to experimentally characterize the effects of Mg content, part positioning on the build plate and scan sequence on the LPBF process robustness.
The main goals expected to be achieved are:
• Become familiar with selective laser melting processes and our experimental platform
• Design a set of experiments for generating data
• Build components on the machine using the designed protocol
• Analyze the manufactured parts (e. g. Archimede density, optical porosity, surface roughness)
In this project, our aim is to experimentally characterize the effects of Mg content, part positioning on the build plate and scan sequence on the LPBF process robustness. The main goals expected to be achieved are: • Become familiar with selective laser melting processes and our experimental platform • Design a set of experiments for generating data • Build components on the machine using the designed protocol • Analyze the manufactured parts (e. g. Archimede density, optical porosity, surface roughness)
Please send your resume/CV (including lists of relevant publications/projects) and transcript of records in PDF format via email to turani@inspire.ethz.ch
Please send your resume/CV (including lists of relevant publications/projects) and transcript of records in PDF format via email to turani@inspire.ethz.ch