Home Industry Additive manufacturing of closed impellers: challenges and progress

Additive manufacturing of closed impellers: challenges and progress

The additive manufacturing of closed impellers made of 316L stainless steel using Laser Powder Bed Fusion (LPBF) opens up new perspectives for industrial applications. A recent study carried out on the Eplus3D Metal Powder Bed Fusion machine investigated the challenges and process parameters that are crucial for the successful production of these complex components.

The manufacturing process of closed impellers places high demands on the geometry, energy supply and material properties. The study analyzed the influence of build angles, energy parameters and surface properties on the quality of the printed parts. A value of 30 degrees proved to be the optimum build angle, achieving the best results in terms of stability and surface quality. At build angles of 0 or 90 degrees, defects occurred more frequently, which can impair functionality.

A key finding was the importance of the energy distribution between the “in-skin” and “down-skin” zones. An energy distribution of 80 to 100 percent of the “in-skin” energy density in the “down-skin” zone led to defect-free components. However, if the energy density was too low, around 20 percent, damage and burns occurred. The optimum energy density of 55.55 J/mm³ reduced the surface roughness to 12.79 µm and minimized unmelted powder during the process.

The hardness values of the impeller were between 226 and 233 HV and reached their maximum value at an energy density of 41.66 J/mm³. These properties underline the precision and adaptability of LPBF technology, particularly in the production of challenging geometries such as closed impellers.

The results of this study show that precise control of the pressure parameters is crucial for the quality and cost-effectiveness of the components. The knowledge gained provides a solid basis for the further development of additive manufacturing technologies in an industrial environment.


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