This project will investigate how build setup and process parameters affect the risk of failed prints in polymer powder bed fusion (PBF) processes, linking this to process productivity and the cost of producing parts. Additionally, the research will explore the network effects of multiple-PBF-machine setups, and how these influence the cost and risk of failure. This research will extend our understanding of the true cost of parts produced using AM, helping manufacturers to assess when and where AM is economically feasible.

The time taken between conception and fabrication in additive manufacturing (AM) is generally faster than wrought parts, since there is no need to create moulds or various machining programmes.  However, the time taken to simply produce one part by AM can exceed 24 hours in some instances.  This research seeks to improve the production rate of Powder Bed Fusion, primarily through processing of larger layer thicknesses (typically >60µm) as well as optimisation of machine parameters and feedstock properties.

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Nickel-based superalloys are mostly used in the aerospace industry due to their superior mechanical performance. The project is set out to study the fatigue behaviour of Inconel 718 manufactured by selective laser melting (SLM). This is realised by testing compact-tension (CT) specimens under high cycle fatigue at room temperature.

 

 

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