Selective laser melting of Inconel 625 using pulse shaping

Abstract

Purpose – The purpose of this paper is to investigate the selective laser melting (SLM) of Inconel 625 using pulse shape control to vary the energy distribution within a single laser pulse. It aims to discuss the effectiveness of pulse shaping, including potential benefits for use within SLM. Design/methodology/approach – Laser parameters were varied in order to identify optimal parameters that produced thin wall parts with a low surface roughness without the use of pulse shape control. Pulse shape control was then employed to provide gradual heating or a prolonged cooling effect with a variety of peak power/pulse energy combinations. Properties of pulse shaped and nonpulse shaped parts were compared, with particular attention focused on part surface roughness and width. Findings – High peak powers tended to reduce top surface roughness and reduce side roughness as recoil pressures flatten out the melt pool and inhibit melt pool instabilities from developing. Ramp up energy distribution can reduce the maximum peak power required to melt material and reduce material spatter generation during processing due to a localized preheating effect. Ramp down energy distribution prolonged melt pool solidification allowing more time for molten material to redistribute, subsequently reducing the top surface roughness of parts. However, larger melt pools and longer solidification times increased the side roughness of parts due to a possible lateral expulsion of material from the melt pool. Originality/value – This paper is the first of its kind to employ laser pulse shape control during SLM to process material from powder bed. It is a useful aid in unveiling relationships between laser energy distribution and the formation of parts.