Gas-tight means zero defects - design considerations for thin-walled fluidic devices with overhangs by laser powder bed fusion

Grinschek, Fabian; Charles, Amal; Elkaseer, Ahmed; Klahn, Christoph; Scholz, Steffen; Dittmeyer, Roland

doi:10.1016/j.matdes.2022.111174

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Gas-tight means zero defects - design considerations for thin-walled fluidic devices with overhangs by laser powder bed fusion

Fabian Grinschek, Amal Charles, Ahmed Elkaseer, Christoph Klahn, Steffen Scholz, Roland Dittmeyer

Materials and Design, Volume: 223, Start page: 111174

Swansea University Author: Steffen Scholz

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DOI (Published version): 10.1016/j.matdes.2022.111174

Abstract

The industrial adoption of additive manufacturing (AM) technologies increased due to more applications and use cases demonstrating significant functional benefits. Additive manufacturing of thin-walled gas-tight structures with complex shapes can fulfil requirements for a wide range of applications,...

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Published in:	Materials and Design
ISSN:	0264-1275
Published:	Elsevier BV 2022
Online Access:	Check full text
URI:	https://cronfa.swan.ac.uk/Record/cronfa61326
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spelling	2022-10-13T11:58:14.8199483 v2 61326 2022-09-26 Gas-tight means zero defects - design considerations for thin-walled fluidic devices with overhangs by laser powder bed fusion 20c4a48c9bf558852c28f1640e01ef50 Steffen Scholz Steffen Scholz true false 2022-09-26 FGSEN The industrial adoption of additive manufacturing (AM) technologies increased due to more applications and use cases demonstrating significant functional benefits. Additive manufacturing of thin-walled gas-tight structures with complex shapes can fulfil requirements for a wide range of applications, such as process equipment for the chemical industry. The requirement to be gas-tight makes the manufacturing process very fault-sensitive as even a single open pore in the submicron range can lead to an impermissible leak of hazardous gases. Further, it has always been a challenge to make thin walls using Laser Powder Bed Fusion of Metals (PBF-LB/M). We explore the key design limit of inclined overhanging gas-tight thin walls made from 316l. A double pass scan strategy is presented to realize these structures along with guidelines to be followed when attempting to print these structures. The paper reports the common failure modes where leaks occur and lessons learned to successful design and printing of gas-tight walls. The results show that fabrication of gas-tight walls is feasible even for a 30° inclination angle to the horizontal and wall thicknesses in the range of 200–300 µm. A case study shows the successful the application of the findings to the production of modular distillation devices. Journal Article Materials and Design 223 111174 Elsevier BV 0264-1275 Laser powder bed fusion; Thin walls; Gas-tight; Water-tight; Leak detection; Effects of defects 1 11 2022 2022-11-01 10.1016/j.matdes.2022.111174 COLLEGE NANME Science and Engineering - Faculty COLLEGE CODE FGSEN Swansea University This work was funded by Deutsche Forschungsgemeinschaft (DFG, German Research Foundation) – SFB 1441 – Project-ID 426888090 2022-10-13T11:58:14.8199483 2022-09-26T10:27:59.0509806 Faculty of Science and Engineering School of Engineering and Applied Sciences - Uncategorised Fabian Grinschek 1 Amal Charles 2 Ahmed Elkaseer 3 Christoph Klahn 4 Steffen Scholz 5 Roland Dittmeyer 6 61326__25436__8fb91da429a9465eaa7c73827317e476.pdf 61326_VoR.pdf 2022-10-13T11:57:23.9478577 Output 3396617 application/pdf Version of Record true Copyright: 2022 The Authors. This is an open access article under the CC BY license true eng http://creativecommons.org/licenses/by/4.0/
title	Gas-tight means zero defects - design considerations for thin-walled fluidic devices with overhangs by laser powder bed fusion
spellingShingle	Gas-tight means zero defects - design considerations for thin-walled fluidic devices with overhangs by laser powder bed fusion Steffen Scholz
title_short	Gas-tight means zero defects - design considerations for thin-walled fluidic devices with overhangs by laser powder bed fusion
title_full	Gas-tight means zero defects - design considerations for thin-walled fluidic devices with overhangs by laser powder bed fusion
title_fullStr	Gas-tight means zero defects - design considerations for thin-walled fluidic devices with overhangs by laser powder bed fusion
title_full_unstemmed	Gas-tight means zero defects - design considerations for thin-walled fluidic devices with overhangs by laser powder bed fusion
title_sort	Gas-tight means zero defects - design considerations for thin-walled fluidic devices with overhangs by laser powder bed fusion
author_id_str_mv	20c4a48c9bf558852c28f1640e01ef50
author_id_fullname_str_mv	20c4a48c9bf558852c28f1640e01ef50_***_Steffen Scholz
author	Steffen Scholz
author2	Fabian Grinschek Amal Charles Ahmed Elkaseer Christoph Klahn Steffen Scholz Roland Dittmeyer
format	Journal article
container_title	Materials and Design
container_volume	223
container_start_page	111174
publishDate	2022
institution	Swansea University
issn	0264-1275
doi_str_mv	10.1016/j.matdes.2022.111174
publisher	Elsevier BV
college_str	Faculty of Science and Engineering
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hierarchy_parent_title	Faculty of Science and Engineering
department_str	School of Engineering and Applied Sciences - Uncategorised{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Uncategorised
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description	The industrial adoption of additive manufacturing (AM) technologies increased due to more applications and use cases demonstrating significant functional benefits. Additive manufacturing of thin-walled gas-tight structures with complex shapes can fulfil requirements for a wide range of applications, such as process equipment for the chemical industry. The requirement to be gas-tight makes the manufacturing process very fault-sensitive as even a single open pore in the submicron range can lead to an impermissible leak of hazardous gases. Further, it has always been a challenge to make thin walls using Laser Powder Bed Fusion of Metals (PBF-LB/M). We explore the key design limit of inclined overhanging gas-tight thin walls made from 316l. A double pass scan strategy is presented to realize these structures along with guidelines to be followed when attempting to print these structures. The paper reports the common failure modes where leaks occur and lessons learned to successful design and printing of gas-tight walls. The results show that fabrication of gas-tight walls is feasible even for a 30° inclination angle to the horizontal and wall thicknesses in the range of 200–300 µm. A case study shows the successful the application of the findings to the production of modular distillation devices.
published_date	2022-11-01T04:20:05Z
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Gas-tight means zero defects - design considerations for thin-walled fluidic devices with overhangs by laser powder bed fusion

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