Recent advancements in laser powder bed fusion (LPBF) technology are set to revolutionize the construction sector, particularly in the production of complex metal components. A groundbreaking study led by Orhan Gülcan from General Electric Aerospace’s Türkiye Technology Center has unveiled critical insights into how overhang and recoater angles affect the quality of parts produced using this innovative technique. Published in the journal Materials Research Express, the research highlights the potential for enhanced manufacturing processes that could significantly reduce production costs and improve component durability.
The study specifically examined the impact of overhang angles on the surface roughness of CoCr material components. Gülcan and his team found that decreasing the overhang angle resulted in increased surface roughness, which can compromise the performance and aesthetics of finished parts. “Understanding these parameters is crucial for optimizing the LPBF process, especially when dealing with intricate designs that require overhangs,” Gülcan noted. The researchers discovered that a 90-degree orientation of the part with respect to the recoater direction yielded the best surface quality, suggesting a clear path for manufacturers aiming to enhance their production techniques.
Moreover, the research delved into the challenges posed by contactless support structures. While these supports offer design flexibility, they lacked the necessary structural integrity for certain angles, particularly the 20-degree overhang, which ultimately failed during manufacturing. This finding underscores the importance of selecting appropriate support mechanisms to ensure the successful production of complex geometries.
The study also incorporated thermomechanical modeling to simulate the LPBF process, revealing a strong correlation between the numerical predictions and experimental results. Gülcan emphasized the value of this modeling approach, stating, “Performing thermomechanical simulations prior to production can significantly mitigate risks such as recoater jams, which can lead to costly downtimes.”
As the construction industry increasingly adopts additive manufacturing technologies, the implications of this research are profound. The ability to produce high-quality, complex metal parts with reduced surface roughness can streamline production processes, enhance the performance of components, and ultimately lead to more sustainable construction practices. With the insights gained from Gülcan’s study, manufacturers can refine their approaches to LPBF, ensuring that they remain competitive in an ever-evolving market.
For those interested in exploring these findings further, the study is available in Materials Research Express, a journal dedicated to advancing materials science research. Gülcan’s work not only paves the way for future developments in LPBF technology but also exemplifies how scientific research can directly influence commercial practices in the construction sector. For more information about the General Electric Aerospace Türkiye Technology Center, visit General Electric Aerospace, Türkiye Technology Center.
