材料特性和工艺参数对增材制造中铺展过程的影响
The influence of material properties and process parameters on the spreading process in additive manufacturing
摘要：
激光粉末床熔融（LPBF）是一种增材制造（AM）技术。为了实现高产品质量，粉末最好以均匀、致密的层形式铺展。LPBF制造商面临的挑战是开发一种铺展工艺，该工艺可以为所使用的许多粉末产生一致的层质量，这些粉末在铺展性方面表现出相当大的差异。因此，我们研究了材料性能、工艺参数和涂敷工具类型对层质量的影响。离散粒子法被用来模拟铺展过程，并定义度量来评估粉末层特性。我们发现，在滚动阻力和颗粒间滑动摩擦以及颗粒内聚力方面的颗粒形状和表面粗糙度都对粉末层质量具有主要（有时令人惊讶）影响：更不规则形状的颗粒、更粗糙的颗粒表面和/或更高的界面内聚力通常但不总是导致更差的铺展性。我们的研究结果表明，材料性能和工艺参数之间存在权衡。增加铺展速度会降低无粘性和弱粘性粉末的层质量，但会改善强粘性粉末的层质量。使用逆时针旋转辊作为铺展工具与使用刀片铺展相比提高了粉末层质量。最后，对于这两种几何形状，一个独特的质量标准的均匀性和质量分数之间的相关性的报告和一些调查结果是有关的尺寸偏析在蔓延。
英文摘要：
Laser powder bed fusion (LPBF) is an additive manufacturing (AM) technology. To achieve high product quality, the powder is best spread as a uniform, dense layer. The challenge for LPBF manufacturers is to develop a spreading process that can produce a consistent layer quality for the many powders used, which show considerable differences in spreadability. Therefore, we investigate the influence of material properties, process parameters and the type of spreading tool on the layer quality. The discrete particle method is used to simulate the spreading process and to define metrics to evaluate the powder layer characteristics. We found that particle shape and surface roughness in terms of rolling resistance and interparticle sliding friction as well as particle cohesion all have a major (sometimes surprising) influence on the powder layer quality: more irregular shaped particles, rougher particle surfaces and/or higher interfacial cohesion usually, but not always, lead to worse spreadability. Our findings illustrate that there is a trade-off between material properties and process parameters. Increasing the spreading speed decreases layer quality for non- and weakly cohesive powders, but improves it for strongly cohesive ones. Using a counter-clockwise rotating roller as a spreading tool improves the powder layer quality compared to spreading with a blade. Finally, for both geometries, a unique correlation between the quality criteria uniformity and mass fraction is reported and some of the findings are related to size-segregation during spreading.
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