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Gas Flow Modelling and Validation for the Design of New Particulate Collection Systems in Laser Powder Bed Fusion / DANIEL BUTCHER

Swansea University Author: DANIEL BUTCHER

  • E-Thesis – open access under embargo until: 27th March 2029

DOI (Published version): 10.23889/SUthesis.66102

Abstract

This project aimed to create a reusable filter system that effectively removes fine metallic particles generated during the Laser Beam Powder Bed Fusion (LBPF) process, which would improve the sustainability of the manufacturing process and its environmental impact. The study investigated various ga...

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Published: Swansea, Wales, UK 2024
Institution: Swansea University
Degree level: Doctoral
Degree name: EngD
Supervisor: Lavery, N.P. ; Brown, S.G.R
URI: https://cronfa.swan.ac.uk/Record/cronfa66102
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first_indexed 2024-04-20T12:23:43Z
last_indexed 2024-04-20T12:23:43Z
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spelling v2 66102 2024-04-20 Gas Flow Modelling and Validation for the Design of New Particulate Collection Systems in Laser Powder Bed Fusion 9535dcbc9c7647ad356832c0fddfadad DANIEL BUTCHER DANIEL BUTCHER true false 2024-04-20 This project aimed to create a reusable filter system that effectively removes fine metallic particles generated during the Laser Beam Powder Bed Fusion (LBPF) process, which would improve the sustainability of the manufacturing process and its environmental impact. The study investigated various gas-separation techniques, including magnetic and cyclone, to optimise particulate collec-tion systems in LBPF. Ultimately, the study chose the cyclone technique used with the existing disposable safe-change filter.The gas flow inside the system was simulated using Computational Fluid Dynamics (CFD) software, and the results were validated through experimental techniques. A 3D metallic printable cyclone system design was created specifically for a Renishaw AM500 LPBF machine, and the proposed cyclone design was manufactured using a Renishaw AM400 and assembled to a RenAM 500M for validation and testing.The study found that the proposed cyclone design was highly effective in capturing and re-moving micron and nano-sized particles generated during the LPBF process, and it extended the operating lifetime of the standard disposable safe-change filter by up to sixteen times. Adding an interchangeable lattice wall further improved the cyclone design by removing additional and smaller particle sizes. Another design variant with conformal cooling was also tested, and the re-sults showed that gas cooling by heat exchangers could reduce larger spatter particles.In summary, the optimised filter system for LBPF developed in this study has the potential to improve the sustainability of the manufacturing process and its environmental impact, as well as extend the lifetime and reduce the costs of existing filter systems. This would make LBPF a more competitive Additive Manufacturing (AM) technique, especially in key markets such as aerospace and medicine. Further testing of lattice design variations is needed, but this research represents a promising step towards improving the LBPF process. E-Thesis Swansea, Wales, UK Additive Manufacturing, Laser Powder Bed Fusion, Gas-Solid Separation, CFD, Experimental Testing 27 3 2024 2024-03-27 10.23889/SUthesis.66102 COLLEGE NANME COLLEGE CODE Swansea University Lavery, N.P. ; Brown, S.G.R Doctoral EngD M2A M2A 2024-04-22T09:39:11.1505984 2024-04-20T13:18:59.3856122 Faculty of Science and Engineering School of Engineering and Applied Sciences - Materials Science and Engineering DANIEL BUTCHER 1 Under embargo Under embargo 2024-04-20T13:41:42.6834465 Output 108381401 application/pdf E-Thesis – open access true 2029-03-27T00:00:00.0000000 Copyright: The author, Daniel Butcher, 2024. true eng
title Gas Flow Modelling and Validation for the Design of New Particulate Collection Systems in Laser Powder Bed Fusion
spellingShingle Gas Flow Modelling and Validation for the Design of New Particulate Collection Systems in Laser Powder Bed Fusion
DANIEL BUTCHER
title_short Gas Flow Modelling and Validation for the Design of New Particulate Collection Systems in Laser Powder Bed Fusion
title_full Gas Flow Modelling and Validation for the Design of New Particulate Collection Systems in Laser Powder Bed Fusion
title_fullStr Gas Flow Modelling and Validation for the Design of New Particulate Collection Systems in Laser Powder Bed Fusion
title_full_unstemmed Gas Flow Modelling and Validation for the Design of New Particulate Collection Systems in Laser Powder Bed Fusion
title_sort Gas Flow Modelling and Validation for the Design of New Particulate Collection Systems in Laser Powder Bed Fusion
author_id_str_mv 9535dcbc9c7647ad356832c0fddfadad
author_id_fullname_str_mv 9535dcbc9c7647ad356832c0fddfadad_***_DANIEL BUTCHER
author DANIEL BUTCHER
author2 DANIEL BUTCHER
format E-Thesis
publishDate 2024
institution Swansea University
doi_str_mv 10.23889/SUthesis.66102
college_str Faculty of Science and Engineering
hierarchytype
hierarchy_top_id facultyofscienceandengineering
hierarchy_top_title Faculty of Science and Engineering
hierarchy_parent_id facultyofscienceandengineering
hierarchy_parent_title Faculty of Science and Engineering
department_str School of Engineering and Applied Sciences - Materials Science and Engineering{{{_:::_}}}Faculty of Science and Engineering{{{_:::_}}}School of Engineering and Applied Sciences - Materials Science and Engineering
document_store_str 0
active_str 0
description This project aimed to create a reusable filter system that effectively removes fine metallic particles generated during the Laser Beam Powder Bed Fusion (LBPF) process, which would improve the sustainability of the manufacturing process and its environmental impact. The study investigated various gas-separation techniques, including magnetic and cyclone, to optimise particulate collec-tion systems in LBPF. Ultimately, the study chose the cyclone technique used with the existing disposable safe-change filter.The gas flow inside the system was simulated using Computational Fluid Dynamics (CFD) software, and the results were validated through experimental techniques. A 3D metallic printable cyclone system design was created specifically for a Renishaw AM500 LPBF machine, and the proposed cyclone design was manufactured using a Renishaw AM400 and assembled to a RenAM 500M for validation and testing.The study found that the proposed cyclone design was highly effective in capturing and re-moving micron and nano-sized particles generated during the LPBF process, and it extended the operating lifetime of the standard disposable safe-change filter by up to sixteen times. Adding an interchangeable lattice wall further improved the cyclone design by removing additional and smaller particle sizes. Another design variant with conformal cooling was also tested, and the re-sults showed that gas cooling by heat exchangers could reduce larger spatter particles.In summary, the optimised filter system for LBPF developed in this study has the potential to improve the sustainability of the manufacturing process and its environmental impact, as well as extend the lifetime and reduce the costs of existing filter systems. This would make LBPF a more competitive Additive Manufacturing (AM) technique, especially in key markets such as aerospace and medicine. Further testing of lattice design variations is needed, but this research represents a promising step towards improving the LBPF process.
published_date 2024-03-27T09:39:09Z
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score 11.016235

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