Methodology for geometric characterization and dimensioning of additively manufactured channels

T. Dahmen*, C. G. Klingaa, S. Baier, D. B. Pedersen, J. H. Hattel

*Corresponding author for this work

Research output: Chapter in Book/Report/Conference proceedingConference abstract in proceedingsResearchpeer-review

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Abstract

Metal additive manufacturing has the potential to enhance the performance of engineering applications by utilizing its inherent design freedom to create complex geometries such as required for conformal cooling. However, additively manufactured channels show significant form deviations when made by laser powder bed fusion. Thereby, not only process-parameters have an influence, but also design-parameters, such as the assigned build direction and the chosen diameter, matter. From a precision manufacturing point of view, there is a need to understand these interdependencies in order to control the deviations. Hence, this work introduces a standardized methodology to quantify and manage the influence of design-parameters on form deviations under a given set of process-parameters. The methodology utilizes two different kinds of test artefacts that are non-destructively analyzed by X-ray computed tomography and light optical microscopy. The results show a proportional influence of build direction and a degressive influence of diameter on cross-sectional area reductions. A resulting prediction model and lookup table serves as a foundation for design engineers to counteract form deviations by pre-processing the CAD-data accordingly. Moreover, this contribution and its artefacts can be utilized as a standard for benchmarking and process-optimization of additively manufactured channels in the future.
Original languageEnglish
Title of host publicationProceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019)
EditorsA. Bernard, R.K. Leach, D.B. Pedersen, J.S. Taylor
PublisherThe European Society for Precision Engineering and Nanotechnology
Publication date2019
Pages133-136
ISBN (Electronic)978-0-9957751-5-2
Publication statusPublished - 2019
EventJoint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing - Ecole Centrale de Nantes, Nantes, France
Duration: 16 Sep 201918 Sep 2019

Conference

ConferenceJoint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing
LocationEcole Centrale de Nantes
CountryFrance
CityNantes
Period16/09/201918/09/2019

Keywords

  • Metal additive manufacturing
  • Design for additive
  • Design guidelines
  • Conformal cooling
  • Laser powder bed fusion
  • 17-4PH

Cite this

Dahmen, T., Klingaa, C. G., Baier, S., Pedersen, D. B., & Hattel, J. H. (2019). Methodology for geometric characterization and dimensioning of additively manufactured channels. In A. Bernard, R. K. Leach, D. B. Pedersen, & J. S. Taylor (Eds.), Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019) (pp. 133-136). The European Society for Precision Engineering and Nanotechnology.
Dahmen, T. ; Klingaa, C. G. ; Baier, S. ; Pedersen, D. B. ; Hattel, J. H. / Methodology for geometric characterization and dimensioning of additively manufactured channels. Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019). editor / A. Bernard ; R.K. Leach ; D.B. Pedersen ; J.S. Taylor. The European Society for Precision Engineering and Nanotechnology, 2019. pp. 133-136
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abstract = "Metal additive manufacturing has the potential to enhance the performance of engineering applications by utilizing its inherent design freedom to create complex geometries such as required for conformal cooling. However, additively manufactured channels show significant form deviations when made by laser powder bed fusion. Thereby, not only process-parameters have an influence, but also design-parameters, such as the assigned build direction and the chosen diameter, matter. From a precision manufacturing point of view, there is a need to understand these interdependencies in order to control the deviations. Hence, this work introduces a standardized methodology to quantify and manage the influence of design-parameters on form deviations under a given set of process-parameters. The methodology utilizes two different kinds of test artefacts that are non-destructively analyzed by X-ray computed tomography and light optical microscopy. The results show a proportional influence of build direction and a degressive influence of diameter on cross-sectional area reductions. A resulting prediction model and lookup table serves as a foundation for design engineers to counteract form deviations by pre-processing the CAD-data accordingly. Moreover, this contribution and its artefacts can be utilized as a standard for benchmarking and process-optimization of additively manufactured channels in the future.",
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Dahmen, T, Klingaa, CG, Baier, S, Pedersen, DB & Hattel, JH 2019, Methodology for geometric characterization and dimensioning of additively manufactured channels. in A Bernard, RK Leach, DB Pedersen & JS Taylor (eds), Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019). The European Society for Precision Engineering and Nanotechnology, pp. 133-136, Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing, Nantes, France, 16/09/2019.

Methodology for geometric characterization and dimensioning of additively manufactured channels. / Dahmen, T.; Klingaa, C. G.; Baier, S.; Pedersen, D. B.; Hattel, J. H.

Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019). ed. / A. Bernard; R.K. Leach; D.B. Pedersen; J.S. Taylor. The European Society for Precision Engineering and Nanotechnology, 2019. p. 133-136.

Research output: Chapter in Book/Report/Conference proceedingConference abstract in proceedingsResearchpeer-review

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AU - Baier, S.

AU - Pedersen, D. B.

AU - Hattel, J. H.

PY - 2019

Y1 - 2019

N2 - Metal additive manufacturing has the potential to enhance the performance of engineering applications by utilizing its inherent design freedom to create complex geometries such as required for conformal cooling. However, additively manufactured channels show significant form deviations when made by laser powder bed fusion. Thereby, not only process-parameters have an influence, but also design-parameters, such as the assigned build direction and the chosen diameter, matter. From a precision manufacturing point of view, there is a need to understand these interdependencies in order to control the deviations. Hence, this work introduces a standardized methodology to quantify and manage the influence of design-parameters on form deviations under a given set of process-parameters. The methodology utilizes two different kinds of test artefacts that are non-destructively analyzed by X-ray computed tomography and light optical microscopy. The results show a proportional influence of build direction and a degressive influence of diameter on cross-sectional area reductions. A resulting prediction model and lookup table serves as a foundation for design engineers to counteract form deviations by pre-processing the CAD-data accordingly. Moreover, this contribution and its artefacts can be utilized as a standard for benchmarking and process-optimization of additively manufactured channels in the future.

AB - Metal additive manufacturing has the potential to enhance the performance of engineering applications by utilizing its inherent design freedom to create complex geometries such as required for conformal cooling. However, additively manufactured channels show significant form deviations when made by laser powder bed fusion. Thereby, not only process-parameters have an influence, but also design-parameters, such as the assigned build direction and the chosen diameter, matter. From a precision manufacturing point of view, there is a need to understand these interdependencies in order to control the deviations. Hence, this work introduces a standardized methodology to quantify and manage the influence of design-parameters on form deviations under a given set of process-parameters. The methodology utilizes two different kinds of test artefacts that are non-destructively analyzed by X-ray computed tomography and light optical microscopy. The results show a proportional influence of build direction and a degressive influence of diameter on cross-sectional area reductions. A resulting prediction model and lookup table serves as a foundation for design engineers to counteract form deviations by pre-processing the CAD-data accordingly. Moreover, this contribution and its artefacts can be utilized as a standard for benchmarking and process-optimization of additively manufactured channels in the future.

KW - Metal additive manufacturing

KW - Design for additive

KW - Design guidelines

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M3 - Conference abstract in proceedings

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BT - Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019)

A2 - Bernard, A.

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A2 - Taylor, J.S.

PB - The European Society for Precision Engineering and Nanotechnology

ER -

Dahmen T, Klingaa CG, Baier S, Pedersen DB, Hattel JH. Methodology for geometric characterization and dimensioning of additively manufactured channels. In Bernard A, Leach RK, Pedersen DB, Taylor JS, editors, Proceedings of the Joint Special Interest Group meeting between euspen and ASPE Advancing Precision in Additive Manufacturing (2019). The European Society for Precision Engineering and Nanotechnology. 2019. p. 133-136