Additive Technologies in Metallurgy & Mechanical Engineering

Сourse
«Additive Technologies in Metallurgy &

Mechanical Engineering»
Liudmila Radionova
Lecture notes
Topic 1. Features of SLS, SLM and DMLS technologies
SLS (Selective Laser Sintering) is an additive manufacturing method, which
consists of melting fine powder material using a laser. Last week we already talked about
selective laser fusion, but then it was about 3D prototyping and machines using polymer
powder as a raw material. Today we will talk about machines that work with metal powder.
One of the varieties of SLS-technology, when it is realized using layer-by-layer
laser melting of metal powders is commonly called SLM (Selective Laser Melting).
Besides SLM there is also a method which is also a kind of SLS-technology. Direct Metal
Laser Sintering (DMLS).
Selective Laser Melting (SLM) and Direct Metal Laser Sintering (DMLS) are two
additive manufacturing processes that belong to the 3D printing group, using the powder
layering method. These two technologies have much in common: both use a laser to melt
metal powder particles selectively, binding them together and creating a model layer by
layer. In addition, the materials used in both processes are metals in granular form.
The differences between SLM and DMLS are connected with the basics of the
particle binding process: SLM uses metal powders with the same melting point and
completely melts the particles, whereas in DMLS the powder consists of materials with
variable melting points. SLM produces parts from a single metal, while DMLS produces
parts from metal alloys. In the case of (DMLS) direct laser sintering, laser energy is
sufficient to melt fine particles and to melt the surface of large particles partially.
Therefore, the fine fraction acts as a binding material when creating the product, and the
large fraction is the main structural component of the material. Thus, in DMLS-technology
the main mechanisms for joining the particles are solid-phase and liquid-phase sintering.
In contrast to classical liquid-phase sintering in the DMLS process, the fusion of particles
occurs locally during accelerated crystallization of the liquid phase.
Both SLM and DMLS technologies are used in industry in order to create final
engineering products. They are very widely used in mechanical engineering. This is due
to the fact that this technology makes it possible to produce parts with very complex
geometry. It is almost impossible to repeat such products using conventional milling or
lathe machines. They have no glues, joints or seams. Because of that, the part gets better
performance characteristics.
The principle of operation of SLS and DMLS devices are very similar.
The camera in which printing takes place is first filled with an inert gas (e.g. argon)
to minimize oxidation of metal powder. Then it is heated to the optimum operating
temperature.
The powder layer is distributed over the platform, a powerful laser makes the
passes along a given trajectory in the program, fusing the metal particles together and
creating the next layer. When the sintering process is complete, the platform moves down
by 1 layer. Then another thin layer of metal powder is applied. The process is repeated
until the printing of the entire model is completed. Then the 3D printer camera is cooled
down to room temperature, the excess powder is removed manually, for example, with a
brush. After that, the parts are usually heat treated while they are still attached to the
platform. This is done to relieve any residual stresses. Further processing can be carried
out with them. The workpiece is removed from the platform by cutting.
The main advantage of DMLS compared to SLM is that it enables to create objects
without any residual stresses and internal defects that can affect the traditionally
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produced metal components. This is extremely important for metal components that will
work under high loads, such as parts in aerospace or automotive industry.
SLM is a process with very high energy because each layer of metal powder must
be heated to the temperature above the melting point of the metal. The high temperature
gradients occurring in the production of SLM can also lead to stresses and dislocations
within the final product, which can impair its physical properties. The metal components
manufactured traditionally must be heat treated after manufacture in order to relieve
internal stresses. However, selective laser melting, namely SLM also has advantages
allowing printing objects extremely densely and firmly.
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This course was developed with the support of the "Open
Polytech" educational project
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