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pps proceeding
Symposium: S14 - Additive Manufactoring
Oral Presentation
 
 

Flow Behaviour of Laser Sintering Powders at Elevated Temperatures

Van den Eynde Michael (1)*, Van Puyvelde Peter (1)

(1) KU Leuven - Vlaams-Brabant - Belgium

Powder flowability is a determining factor in many industrial processes. In laser sintering (LS), for example, a well-flowing powder is required to enable the deposition of smooth layers with a thickness of only 100 µm[1]. Characterising what powders meet these flow requirements is, however, not straightforward. Most industrially used characterisation techniques are indexers, which means their results cannot just be extrapolated to any flow field. This research evaluates the flowability of multiple powders intended for laser sintering. A dynamic angle of repose (dAoR) and Hausner ratio (HR) are used to provide a quick first screening. Powders passing these first tests are then subjected to a spreading experiment, which evaluates layer quality and density. The layer density is directly relevant for the sintering process, as denser powder layers yield mechanically stronger products[2]. Results show that the dAoR is able to provide a quick screening of some powders. However, powders scoring the best in the dAoR are not always the optimal powders for LS. Moreover, flowability at ambient conditions is not a sufficient criterion for LS powders, as the entire process occurs well above room temperature. Powder rheometry, in combination with DSC measurements, is therefore used to assess a maximum bed temperature at which the powder is still spreadable. The spreading experiment is also expanded to incorporate powder heating, mimicking LS even further. Finally, also humidity is taken into account. The moisture content and uptake rate are examined via thermogravimetric analysis. Results on the standard PA12 2200 show that small amounts of moisture decrease the flowability, compared to the dried powder. Moisture content should thus thoroughly be monitored in lab conditions, to provide directly relevant insights for the laser sintering process. 1 R.D. Goodride et al, Prog. in Mater. Sci. 57, 229-267 (2012) 2 T. Niino, K. Sato. Proc. SFF Symposium, Austin, 193-205 (2009)