The development of reliable additive manufacturing (AM) technologies to process metallic materials, e.g. selective laser melting (SLM), has allowed their adoption for manufacturing fnal components. To date, ensuring part quality and process control for low-volume AM productions is still critical because traditional statistical techniques are often not suitable. To this aim, extensive research has been carried out on the optimisation of material properties of SLM parts to prevent defects and guarantee part quality. Amongst all material properties, defects in surface hardness are of particular concern as they may result in an inadequate tribological and wear resistance behaviour. Despite this general interest, a major void still concerns the quantifcation of their extent in terms of probability of defects occurring during the process, although it is optimised. Considering these issues, this paper proposes a novel approach to quantify the probability of occurrence of defects in hardness-optimised parts by SLM. First, three process variables, i.e. laser power, scan speed and hatching distance, are studied considering their efect on hardness. Design of Experiments and Response Surface Methodology are exploited to achieve hardness optimisation by controlling process variables. Then, hardness defect probability is estimated by composing the uncertainty afecting both process variables and their relationship with the hardness. The overall procedure is applied to AlSi10Mg alloy, which is relevant for both aerospace and automotive applications. The approach this study proposes may be of assistance to inspection designers to efectively and efciently set up quality inspections in early design phases of inspection planning.

Defect Probability Estimation for Hardness-Optimised Parts by Selective Laser Melting / Galetto, Maurizio; Genta, Gianfranco; Maculotti, Giacomo; Verna, Elisa. - In: INTERNATIONAL JOURNAL OF PRECISION ENGINEERING AND MANUFACTURING. - ISSN 2234-7593. - 21:9(2020), pp. 1739-1753. [10.1007/s12541-020-00381-1]

Defect Probability Estimation for Hardness-Optimised Parts by Selective Laser Melting

Galetto, Maurizio;Genta, Gianfranco;Maculotti, Giacomo;Verna, Elisa
2020

Abstract

The development of reliable additive manufacturing (AM) technologies to process metallic materials, e.g. selective laser melting (SLM), has allowed their adoption for manufacturing fnal components. To date, ensuring part quality and process control for low-volume AM productions is still critical because traditional statistical techniques are often not suitable. To this aim, extensive research has been carried out on the optimisation of material properties of SLM parts to prevent defects and guarantee part quality. Amongst all material properties, defects in surface hardness are of particular concern as they may result in an inadequate tribological and wear resistance behaviour. Despite this general interest, a major void still concerns the quantifcation of their extent in terms of probability of defects occurring during the process, although it is optimised. Considering these issues, this paper proposes a novel approach to quantify the probability of occurrence of defects in hardness-optimised parts by SLM. First, three process variables, i.e. laser power, scan speed and hatching distance, are studied considering their efect on hardness. Design of Experiments and Response Surface Methodology are exploited to achieve hardness optimisation by controlling process variables. Then, hardness defect probability is estimated by composing the uncertainty afecting both process variables and their relationship with the hardness. The overall procedure is applied to AlSi10Mg alloy, which is relevant for both aerospace and automotive applications. The approach this study proposes may be of assistance to inspection designers to efectively and efciently set up quality inspections in early design phases of inspection planning.
File in questo prodotto:
File Dimensione Formato  
Galetto2020_Article_DefectProbabilityEstimationSLM_IJPEM.pdf

accesso aperto

Descrizione: Articolo completo
Tipologia: 2a Post-print versione editoriale / Version of Record
Licenza: Creative commons
Dimensione 1.52 MB
Formato Adobe PDF
1.52 MB Adobe PDF Visualizza/Apri
Manuscript_JPEM-D-20-00129_versione finale.pdf

non disponibili

Descrizione: Articolo completo
Tipologia: 2. Post-print / Author's Accepted Manuscript
Licenza: Non Pubblico - Accesso privato/ristretto
Dimensione 928.28 kB
Formato Adobe PDF
928.28 kB Adobe PDF   Visualizza/Apri   Richiedi una copia
Pubblicazioni consigliate

Caricamento pubblicazioni consigliate

I documenti in IRIS sono protetti da copyright e tutti i diritti sono riservati, salvo diversa indicazione.

Utilizza questo identificativo per citare o creare un link a questo documento: http://hdl.handle.net/11583/2841160