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<p>Anisotropic behavior of additively manufactured (AM) parts is consistently viewed as one of the main issues that limited the full functionality of AM-printed parts. Several factors can contribute in anisotropy of AM parts including rastering patterns within the XY-plane and layer-based building principle, where a zero angle between printed layers yields weak interlaminar strength. To resolve anisotropy, most studies followed the approach of changing rastering angles within the XY-plane, optimizing parameters of AM technologies, and using within-layers’ heat treatments. Scarce efforts considered changing the build orientations as a possible means of reducing anisotropic behavior of AM parts. This study aims to investigate the effect of a new build angles approach within the XZ-plane as a possible means of reducing the anisotropic behavior of direct metal laser sintering (DMLS) printed parts. A set of margining steel coupons was printed by DMLS using five different build angles within the XZ-plane (0°, ± 30˚, ± 45˚, ± 60˚, and 90°). A laser of Yb-fiber type with a focus diameter of 100&#xa0;µm was used. Nitrogen gas was used as a shielding gas during coupon manufacturing. Hardness, impact, and flexural strength of coupons were tested in addition to analyzing their fracture morphology using scanning electron microscopy. Findings showed that the highest hardness was obtained in coupons printed using a build angle of 45°, whereas the highest values for the impact and flexural strength were obtained at build angles of 60°, and 90°, respectively. More importantly, parts built using an angle of 45° were found to be statistically isotropic in terms of their mechanical properties, unlike the remaining build angles, which exhibit anisotropy.</p>

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Mitigating anisotropy: exploring a new build orientation approach in direct metal laser sintering to print margining steel parts

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年5月21日

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  • Esraa S. Abdelall,
  • Qasem Mahafdeh,
  • Abdullah Al Dwairi,
  • Mu taz Alotein,
  • Mohammad Janaideh

摘要

Anisotropic behavior of additively manufactured (AM) parts is consistently viewed as one of the main issues that limited the full functionality of AM-printed parts. Several factors can contribute in anisotropy of AM parts including rastering patterns within the XY-plane and layer-based building principle, where a zero angle between printed layers yields weak interlaminar strength. To resolve anisotropy, most studies followed the approach of changing rastering angles within the XY-plane, optimizing parameters of AM technologies, and using within-layers’ heat treatments. Scarce efforts considered changing the build orientations as a possible means of reducing anisotropic behavior of AM parts. This study aims to investigate the effect of a new build angles approach within the XZ-plane as a possible means of reducing the anisotropic behavior of direct metal laser sintering (DMLS) printed parts. A set of margining steel coupons was printed by DMLS using five different build angles within the XZ-plane (0°, ± 30˚, ± 45˚, ± 60˚, and 90°). A laser of Yb-fiber type with a focus diameter of 100 µm was used. Nitrogen gas was used as a shielding gas during coupon manufacturing. Hardness, impact, and flexural strength of coupons were tested in addition to analyzing their fracture morphology using scanning electron microscopy. Findings showed that the highest hardness was obtained in coupons printed using a build angle of 45°, whereas the highest values for the impact and flexural strength were obtained at build angles of 60°, and 90°, respectively. More importantly, parts built using an angle of 45° were found to be statistically isotropic in terms of their mechanical properties, unlike the remaining build angles, which exhibit anisotropy.