Investigation of Effects of Spreading Parameters on Powder Bed Quality in Additive Manufacturing

Abstract

Powder bed-based additive manufacturing processes such as laser powder bed fusion, binder jetting, and electron beam melting are commonly utilized in various critical areas such as medical, aviation, and energy. Common to all these operations, the powders are first spread onto the built platform in a layer-by-layer fashion and selectively fused or bound with a suitable method. The quality of the process depends on several process parameters, including how the powders are spread onto the built platform. Powder spreading is an important step in these operations and can affect various process outputs. In this study, the powder spreading is numerically investigated using the discrete element method to determine the effects of the layer thickness, rotation, and transition velocities selected as parameters with a powder spreader roller. The relationship between powder spreading parameters and powder volume packing fraction was investigated using the 'Hertz-Mindlin and Johnson-Kendall-Robert’s (JKR) contact model considering the interactions between particle-particle and particle-built plate, has been added to the numerical model. A Design of Experiment combined with analysis of variance (ANOVA) was utilized to gain a broader understanding on the relationship between process parameters and green density and dynamic angle of repose.