Plume Elimination System for Laser Powder Bed Fusion Additive Manufacturing
Problem statement
Laser powder bed fusion (LPBF) is an additive manufacturing technique that allows parts to have complex geometry made with strong materials. Industries such as aerospace, automotive, and medical rely heavily on LPBF technology for its precision in producing components with enhanced material properties [1]. However, the plume that is emitted during the manufacturing process can disrupt the laser and cause imperfections in the parts. The plume consists of vaporized and partially melted particles and can lead to problems such as porosity, surface roughness, and inconsistencies in products [1]. There is a lack of effective methods to eliminate the plume without causing disruptions in the manufacturing process. Some examples of current strategies to combat this problem include adjusting laser parameters or optimizing the characteristics of the powder. These methods show little success in eliminating defects caused by the plume. LPBF does have a fairly high upfront cost involving equipment and maintenance. While the initial cost of LPBF is high, its long term benefits outweigh the investment due to advancements in the technology that are lowering the cost to make LPBF more accessible to a larger range of industries. The complex yet strong parts that can be made efficiently with LPBF justifies the initial expenses for many industries [1]. Our team intends to create a method that will reduce or completely eliminate the plume so LPBF can reach its full potential for numerous applications such as medical, automotive, and aerospace industries.
[1]S. Chowdhury et al., ‘Laser powder bed fusion: a state-of-the-art review of the technology, materials, properties & defects, and numerical modeling,’ Journal of Materials Research and Technology, vol. 20, pp. 2109-2172, Sep. 2022, doi: 10.1016/J.JMRT.2022.07.121.
Team members
Antony Rainchik – leader
Sy Wallraf – communicator
Aria Murphy – accountant
Natalie Rullman – admin
Client
Lianyi Chen
Department of Mechanical Engineering – UW Madison