Single track formation in selective laser melting of metal powders

Selective laser melting (SLM) is a powder-based additive manufacturing capable to produce parts layer-by-layer from a 3D CAD model. Currently there is a growing interest in industry for applying this technology for generating objects with high geometrical complexity. To introduce SLM process into industry for manufacturing real components, high mechanical properties of final product must be achieved. Properties of manufactured parts depend strongly on each single laser-melted track and each single layer. In this study, effects of the processing parameters such as scanning speed and laser power on single tracks formation are explored. Experiments are carried out at laser power densities (0.3-1.3) x 10(6) W/cm(2) by cw Yb-fiber laser. Optimal ratio between laser power and scanning speed (technological processing map) for 50 mu m layer thickness is determined for stainless steels (SS) grade 316L(-25 mu m) and 904L (-16 mu m), tool steel H13 (-25 mu m), copper alloy CuNi10 (-25 mu m) and superalloy Inconel 625 (-16 mu m) powders. A considerable negative correlation is found between the thermal conductivity of bulk material and the range of optimal scanning speed for the continuous single track sintering. (C) 2010 Elsevier B.V. All rights reserved.