A novel mathematical model for predicting a sustainable selective laser melting and controlled densification

We introduce the innovative concept of Sustainable Laser Energy Consumption (SLEC, ε) that promotes sustainable metal additive manufacturing practices while maintaining productivity and tailored densification in the Selective Laser Melting (SLM) process. This study focuses on deriving analytical exp...

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Bibliographic Details
Published in:International journal of sustainable engineering 2024-12, Vol.17 (1), p.239-249
Main Authors: Estrada-Díaz, Jorge A., Elías-Zúñiga, Alex, Martínez-Romero, Oscar, Palacios-Pineda, Luis M., Guzmán-Nogales, Rigoberto, Cedeño-Viveros, Luis D., Olvera-Trejo, Daniel
Format: Article
Language:English
Subjects:
Additive manufacturing
Beds (process engineering)
Bulk density
Densification
density
Dimensional analysis
Energy consumption
Fractal geometry
Fractals
Homogeneity
Laser beam melting
Lasers
Manufacturing
mathematical modeling
Mathematical models
Melting
Powder
Powder beds
Predictive control
Productivity
Renewable energy
Selective Laser Melting
Sustainability
Sustainable production
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Summary:We introduce the innovative concept of Sustainable Laser Energy Consumption (SLEC, ε) that promotes sustainable metal additive manufacturing practices while maintaining productivity and tailored densification in the Selective Laser Melting (SLM) process. This study focuses on deriving analytical expressions through dimensional analysis and Buckingham's π theorem to predict bulk density with high precision across studied materials: In718, W, AlSi10Mg, Ti6Al4V, and SS316L. This approach provides valuable insights and allows the setting of an appropriate combination of scanning speed and hatch distance for a range of laser power, enabling sustainable manufacturing of SLMed components with tailored density. Furthermore, the mathematical expression introduced as SLEC facilitates the tradeoff between energy consumption and productivity, promoting a greener and more sustainable future of metal additive manufacturing. Furthermore, the underlying fractal nature of SLM is explored through the investigation of the influence of fractal structures, present in the powder bed, on densification that provides information on how powder morphology and homogeneity (i.e. fractal dimension and lacunarity) of the powder bed are linked to a sustainable SLM process.
ISSN:1939-7038
1939-7046
DOI:10.1080/19397038.2024.2327386