Mr. Simon Hornung Profile

Simon Hornung

at Angewandte Lasertechnik und Photonik

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Proceedings Article | 12 March 2024 Presentation + Paper

Optimization of mechanical properties of additive manufactured IN 718 parts combining LPBF and in-situ high-speed milling

David Sommer, Simon Hornung, Cemal Esen, Ralf Hellmann

Proceedings Volume 12876, 128760E (2024) https://doi.org/10.1117/12.3000952

KEYWORDS: Additive manufacturing, Material fatigue, Materials properties, Manufacturing, Heat treatments, Surface roughness, Surface properties, Spindles, Fabrication, Deformation

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Mechanical properties of Laser Powder Bed Fusion (LPBF) processed components are sensitively affected by the inferior surface quality, typical for this additive manufacturing technique for metal parts. Using a promising hybrid additive manufacturing approach, combining LPBF and in-situ high-speed milling, the surface quality can be strongly improved within a single process cycle. The milling process is directly integrated into the additive manufacturing chamber, machining the 3D-built surfaces while interrupting the LPBF-process. As a result, surface defects and surface near porosities are greatly reduced. Even though Inconel 718 is difficult to machine, as well as the milling process within the powder bed poses different challenges on this promising approach, a surface roughness of Ra ⪅ 1μm is generally achievable, using this particular hybrid additive manufacturing approach. We present a comparative study of the mechanical properties of conventional LPBF- and hybrid-build components with particular focus on the static and dynamic load behavior, in turn allowing to evaluate the effects of finished surfaces on these mechanical properties. In addition, the influence of different heat treatments on the static load behavior as well as the fatigue behavior is investigated. Different heat-treatments are performed, improving the density of the components, and leading to a higher maximum load behavior. Furthermore, the fatigue behavior is modified, as the material properties can be changed by virtue of the development of different material phases during the heat treatment processes. Comparing the sole LPBF- and hybrid-built components for the as-built and the different heat-treated states, an improvement of the maximum load capacity as well as of the dynamic load behavior can be observed for the hybrid-built specimens.

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