Advanced manufacturing: exploration of methods for control and validation of powder bed fusion process in additive manufacturing process

• Grant number: 18/06045-0
• Support Opportunities: Research Grants - Young Investigators Grants
• Start date: May 01, 2023
• End date: April 30, 2028
• Field of knowledge: Engineering - Mechanical Engineering - Manufacturing Processes
• Principal Investigator: Éder Sócrates Najar Lopes
• Grantee: Éder Sócrates Najar Lopes
• Host Institution: Faculdade de Engenharia Mecânica (FEM). Universidade Estadual de Campinas (UNICAMP). Campinas , SP, Brazil
• Associated researchers: André Luiz Jardini Munhoz ; Julian Arnaldo Avila Diaz ; Juliano Soyama ; Milton Sergio Fernandes de Lima ; Pedro Yoshito Noritomi
• Associated research grant(s): 24/02060-5 - Mitigation of retained austenite by compositional modification of AISI H13 tool steel processed by powder bed fusion, AP.R; 23/05806-5 - Multi-user Equipment approved in grant 2018/06045-0: laser powder bed fusion additive manufacturing machine, AP.EMU; 23/05807-1 - Multi-user Equipment approved in grant 2018/06045-0: universal testing machine (100 kN), AP.EMU; 23/05808-8 - Multi-user equipment approved in grant 2018/06045-0: digital image correlation system 3D, AP.EMU
• Associated scholarship(s): 25/05865-7 - EXPERIMENTAL ANALYSIS OF MICROSTRUCTURAL AND MECHANICAL BEHAVIOR OF ARCHITECTURED STRUCTURES MANUFACTURED IN AISIH13 STEEL BY ADDITIVE MANUFACTURING WITH PROGRAMMABLE LASER BEAM, BP.IC; 25/05873-0 - EVALUATION OF CONFORMAL CHANNELS MANUFACTURED IN TOOL STEEL BY ADDITIVE MANUFACTURING WITH PROGRAMMABLE LASER BEAM, BP.IC; 25/02998-6 - COMPUTATIONAL SIMULATION AND EXPERIMENTAL ANALYSIS OF THE MECHANICAL BEHAVIOR OF ARCHITECTURED STRUCTURES MANUFACTURED BY ADDITIVE MANUFACTURING WITH PROGRAMMABLE LASER BEAM, BP.DD; + associated scholarships 24/21005-5 - Influence of processing parameters on different metal alloys processed by PBF-LB using a laser with programmable shape and beam diameter, BP.IC; 24/18806-6 - THREE-DIMENSIONAL MICROSTRUCTURAL CHARACTERIZATION OF SAMPLES MANUFACTURED BY ADDITIVE MANUFACTURING WITH PROGRAMMABLE LASER BEAM, BP.IC; 24/02502-8 - Optimization study of microstructural and mechanical properties of AISI-H13 tool steel samples processed by additive manufacture with programmable laser beam, BP.DD - associated scholarships

Abstract

This Young Investigator Award project, which is aligned with FAPESP's funding initiatives focused on scientific and technological cooperation on advanced manufacturing topics, aims to conduct systematic studies of processing, monitoring and control in the additive manufacturing (AM) process using the powder bed fusion technique with laser beam (PBF-LB). The objectives include: i) the experimental design and computational simulation of the layer deposition process at a micrometric scale and the mechanical behavior of the product; ii) PBF-LB processing of materials with different degrees of absorbance using a high-power laser with programmable heat distribution shape and beam diameter; iii) the exploration of post-processing routes by heat treatment, and finally iv) the microstructural and the mechanical properties characterization of samples. The processability of materials that have distinct processability characteristics will be discussed, such as AISI-H13 (UNS T20813) and Maraging M300 (UNS K93120) steels and CuCrZr alloy (UNS C18150). At the end of the project, the expectation is that the knowledge base will be established for the definition of processing methodologies, post-processing, and characterization of different materials processed by AM PBF-LB. (AU)

Scientific publications

(5)

(References retrieved automatically from Web of Science and SciELO through information on FAPESP grants and their corresponding numbers as mentioned in the publications by the authors)

CONDE, FABIO FARIA; FONSECA, EDUARDO B.; FREIRE, SUYANNY A.; LOPES, EDER S. N.. Impact of Heat Treatments on Residual Stress in Additively Manufactured AISI H13 Tool Steel. Journal of Materials Engineering and Performance, v. N/A, p. 11-pg., 2025-06-11. (24/02502-8, 24/14945-1, 24/02060-5, 18/06045-0, 19/06276-4)

ZLUHAN, BRUNO; NARASIMHARAJU, SHUBHAVARDHAN RAMADURGA; CHOLKAR, ABHIJIT; THOMAS, KEN; RAGHAVENDRA, RAMESH; LOPES, EDER S. N.. Design, defect analysis, compressive strength and surface texture characterization of Laser Powder Bed Fusion processed Ti6Al4V lattice structures. JOURNAL OF MATERIALS RESEARCH AND TECHNOLOGY-JMR&T, v. 35, p. 20-pg., 2025-03-01. (18/06045-0)

ROJAS-ARIAS, N.; UNTI, L. F. K.; VALIM, D. B.; GABRIEL, A. H. G.; FONSECA, E. B.; LOPES, E. S. N.. Microstructural Evolution of PBF-LB AlSi10Mg under Different Heat Treatment Conditions. MATERIALS RESEARCH-IBERO-AMERICAN JOURNAL OF MATERIALS, v. 28, p. 9-pg., 2025-01-01. (18/06045-0)

FONSECA, EDUARDO B.; GABRIEL, ANDRE H. G.; AVILA, JULIAN A.; VAZ, RODOLPHO F.; VALIM, DIEGO B.; CANO, IRENE G.; LOPES, EDER S. N.. Fracture toughness and wear resistance of heat-treated H13 tool steel processed by laser powder bed fusion. ADDITIVE MANUFACTURING, v. 78, p. 17-pg., 2023-11-21. (19/06276-4, 18/06045-0)

FONSECA, EDUARDO B.; GABRIEL, ANDRE H. G.; ROCHA, THIAGO M.; VALIM, DIEGO B.; LOPES, EDER S. N.. A method to evaluate the processability of metallic alloys by laser-based powder bed fusion. MATERIALS TODAY COMMUNICATIONS, v. 44, p. 6-pg., 2025-03-01. (19/06276-4, 18/06045-0)