The Effect of Scanning Strategy On Mechanical Properties and Delamination During Brake Caliper Manufacturing With Selective Laser Melting (SLM)

Year 2024, Volume: 27 Issue: 3, 1129 - 1140, 25.07.2024

Mehmet Özakıncı , Rahmi Ünal

https://doi.org/10.2339/politeknik.1214999

Cited By: 1

Abstract

In the industry, additively manufactured components are becoming more prevalent. Rather than the growth in production of ordinary non-structural components by additive manufacturing, Additive manufacturing's increased safety-critical component production drives this prevalence. Thus, additive manufacturing of the braking system part, a vital subsystem in almost all vehicles, will help spread this manufacturing method. This study investigated the delamination issue noticed during the selective laser melting manufacture of the service brake caliper from 316L stainless steel. All process parameters were kept constant to investigate only the scanning strategy effect on the mechanical properties and delamination. On the samples, density-porosity measurements, tensile and hardness tests, and macrostructure examinations using an optical microscope were conducted. As a consequence of the studies, the chessboard scanning strategy exhibited superior mechanical properties over the stripe scanning strategy. The Chessboard method gave better results by 6% for measuring yield stress and by 12% for measuring Brinell hardness. The delamination was not entirely eliminated by the chessboard scanning strategy; however, it was noticed to be reduced in comparison to the stripe scanning strategy. Possible causes of delamination are discussed with microhardness measurements and optical microscope examinations.

Keywords

SLM (selective laser melting), Delamination, 316L stainless steel, Chessboard Scanning strategy, Stripe Scanning strategy

References

• [1] Yalçın B., Karakılınç U., and Ergene B., “Toz Yataklı/Beslemeli Eklemeli İmalatta Kullanılan Partiküllerin Uygunluk Araştırması ve Partikül İmalat Yöntemleri”, J. Polytech., 22(4): 801–810, (2019).
• [2] Kayacan M. Y. and Yılmaz N., “DMLS Eklemeli İmalatta Süreç Ve Maliyet Modeli Geliştirilmesi”, J. Polytech., 22(3): 763-770, (2019).
• [3] Balcı A., Aycan M. F., Usta Y. and Demir T., “Seçimli Lazer Ergitme İle Ti6Al4V ELI Alaşımından Üretilen Trabeküler Metal Yapıların Basma Ve Basma-Kayma Dayanımlarının İncelenmesi”, J. Polytech., 24(3): 903-914, (2021).
• [4] Yampolskiy M. et al., “Security of additive manufacturing: Attack taxonomy and survey”, Addit. Manuf., 21: 431–457, (2018).
• [5] Mugwagwa L., Yadroitsev I., and Matope S., “Effect of process parameters on residual stresses, distortions, and porosity in selective laser melting of maraging steel 300”, Metals, 9(10): 1042, (2019).
• [6] Ponticelli G. S., Panciroli R., Venettacci S., Tagliaferri F., and Guarino S., “Experimental investigation on the fatigue behavior of laser powder bed fused 316L stainless steel”, CIRP J. Manuf. Sci. Technol., 38: 787–800, (2022).
• [7] Röttger A. et al., “Microstructure and mechanical properties of 316L austenitic stainless steel processed by different SLM devices”, Int. J. Adv. Manuf. Technol., 108(3): 769–783, (2020).
• [8] Moeinfar K., Khodabakhshi F., Kashani-bozorg S. F., Mohammadi M., and Gerlich A. P., “A review on metallurgical aspects of laser additive manufacturing (LAM): Stainless steels, nickel superalloys, and titanium alloys”, J. Mater. Res. Technol., 16: 1029–1068, (2022).
• [9] Carter L. N., Attallah M. M., and Reed R. C., “Laser powder bed fabrication of nickel-base superalloys: Influence of parameters; characterisation, quantification and mitigation of cracking”, Proc. Int. Symp. Superalloys, Pennsylvania, 577–586, (2012).
• [10] Yakout M., Phillips I., Elbestawi M. A., and Fang Q., “In-situ monitoring and detection of spatter agglomeration and delamination during laser-based powder bed fusion of Invar 36”, Opt. Laser Technol., 136: 106741, (2021).
• [11] Qiu C., Al Kindi M., Aladawi A. S., and Al Hatmi I., “A comprehensive study on microstructure and tensile behaviour of a selectively laser melted stainless steel”, Sci. Rep., 8(1): 1–16, (2018).
• [12] Liverani E., Toschi S., Ceschini L., and Fortunato A., “Effect of selective laser melting (SLM) process parameters on microstructure and mechanical properties of 316L austenitic stainless steel”, J. Mater. Process. Technol., 249: 255–263, (2017).
• [13] Kempen K., Vrancken B., Buls S., Thijs L., Van Humbeeck J., and Kruth J. P., “Selective Laser Melting of Crack- Free High Density M2 High Speed Steel Parts by Baseplate Preheating”, J. Manuf. Sci. Eng. Trans. ASME, 136(6): 1– 7, (2014).
• [14] DebRoy T. et al., “Additive manufacturing of metallic components – Process, structure and properties”, Prog. Mater. Sci., 92: 112–224, (2018).
• [15] ASTM E8/E8M-22, “Standard Test Methods for Tension Testing of Metallic Materials”, (2022).
• [16] Öz Ö. and Öztürk F. H., “Yazdırma Açısının 3B Yazıcıda Üretilen PLA Numunenin Mekanik Özellikleri Üzerine Etkisinin Deneysel ve Sonlu Elemanlar Metodu ile İncelenmesi”, J. Polytech., 1-1, (2023).
• [17] ISO 6507-1, “Metallic materials - Vickers hardness test - Part 1: Test method”, (2018).
• [18] ASTM B311-22, “Standard Test Method for Density of Powder Metallurgy (PM) Materials Containing Less Than Two Percent Porosity”, (2022).
• [19] Tüzemen M. Ç., Salamcı E., and Ünal R., “Investigation of the relationship between flexural modulus of elasticity and functionally graded porous structures manufactured by AM”, Mater. Today Commun., 31: 103592, (2022).
• [20] Tüzemen M. Ç., Salamcı E., and Ünal R., “Additive manufacturing design approach to strut-based functionally graded porous structures for personalized implants”, J. Manuf. Process., 84: 1526–1540, (2022).
• [21] Taylor R. P., McClain S. T., and Berry J. T., “Uncertainty analysis of metal-casting porosity measurements using Archimedes’ principle”, Int. J. Cast Met. Res., 11:4, 247-257, (1999).
• [22] https://matweb.com, “MatWeb Material Property Data,” AISI Type 316L Stainless Steel, annealed bar. Available: (Accessed: 03-Nov-2022).
• [23] Kurzynowski T., Stopyra W., Gruber K., Ziólkowski G., Kuznicka B., and Chlebus E., “Effect of scanning and support strategies on relative density of SLM-ed H13 steel in relation to specimen size”, Materials (Basel)., 12(2): 239, (2019).
• [24] Dursun A. M., Tüzemen M. Ç., Salamci E., Yılmaz O. and Ünal R., “Investigation of Compatibility Between Design and Additively Manufactured Parts of Functionally Graded Porous Structures”, J. Polytech., 25(3): 1069- 1082, (2022).
• [25] Gao M., Wang Z., Li X., and Zeng X., “The effect of deposition patterns on the deformation of substrates during direct laser fabrication”, J. Eng. Mater. Technol., 135(3): 034502, (2013).