The Effect of Placement and Powder Reuse on the Fatigue Performance of 3D Printed Parts

(The Effect of Placement and Powder Reuse on the Fatigue Performance of 3D Printed Parts)

Previous studies have found that the fatigue performance of the parts made by
the repeated use of Ti6Al4V under the electron beam powder bed fusion process is
69 times lower than that of the parts made with the unused new powder. The
reason is that the particle surface oxidation leads to the internal fusion of
the parts. defect. In another study, the plasticity and toughness of
nickel-based alloy powders printed by a laser powder bed fusion process for
multiple cycles were reduced.

Taking into account the hypothesis that powder properties may affect the
quality of parts and the needs of industrial applications, the fatigue
performance of 3D printing materials (especially the ultra-high cycle fatigue
performance) has become one of the urgent scientific problems in the field of
additive manufacturing.

The change of powder characteristics and its influence on the effect of
spreading powder:

The powder used in the study is 17-4PH stainless steel, the initial powder
size distribution is between 15-45μm, and the initial quantity of 80kg is used
for 15 consecutive printing. Each time the manufacturing is completed, the
powder is sieved and thoroughly mixed with the unused powder. The effects of the
placement of the parts and the repeated use of powder on the tensile strength
and fatigue life of the parts are studied respectively.

A comprehensive study of materials such as IN718, Ti6Al4V, AlSi10Mg, etc. by
a number of units found that the repeated use of the powder will cause changes
in the characteristics of the powder, mainly as follows:

The fine powder content decreases, the particle size distribution narrows,
and the average particle size increases, especially for AlSi10Mg; the morphology
of the particles will also become more slender (found in some studies); compared
with the unused powder, the cycle has been Due to the disappearance of satellite
powder and long-term high temperature exposure, the moisture content of the
powder is reduced, the phenomenon of powder agglomeration is reduced, and the
fluidity is generally increasing.

The results of the particle size test in this study basically verified the
above conclusions. The particle size width of the initial powder was 45μm, and
the particle size of the 15th batch was 41μm. The particle size of the powder
has become narrower; the powder used repeatedly has smaller inter-particle gaps
than the initial powder. The powder fluidity and filling state are improved. In
general, the repeated use of powder can make spreading more uniform and reduce
the gap between particles. This change increases the complexity of understanding
how powder specifications affect part performance. At the same time, the change
of powder characteristics may bring some changes to the mechanical properties of
parts at different positions on the substrate.

The study of fatigue behavior found that the repeated use of powder has
almost no direct effect on the parts that have not been machined and have
printed surfaces, which is mainly due to the retention of surface roughness;
while for the machined samples, Under low-cycle and medium-cycle fatigue
conditions, continuous repeated use of powder will not affect the fatigue
behavior; however, under high-cycle fatigue conditions, the fatigue life of the
15th batch of samples is significantly higher than that of the first batch. The
study on the fatigue life of the left and right samples found that the fatigue
life of the right sample is higher than that of the left sample, but this gap
will still decrease with the increase in the number of powder usage.

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(The Effect of Placement and Powder Reuse on the Fatigue Performance of 3D Printed Parts)