Multi-objective optimization of forming quality for horizontal circular internal flow channels fabricated using laser powder bed fusion

Abstract

In laser powder bed fusion (LPBF), circular internal flow channels in small aerospace satellite integration plates must be fabricated without supporting structures, particularly for horizontal channels. This can cause melt-pool collapse defects during the LPBF process, leading to reduced relative density, increased surface roughness, and thermal stress-induced deformation. To address these challenges, we developed a multi-objective collaborative optimization forming method for fabricating φ1-mm TC4 horizontal circular internal flow channels via LPBF. Optimal heat treatment parameters were obtained to enhance the corrosion resistance of the internal flow channels. The results revealed that the forming quality of the horizontal circular internal flow channels was comprehensively improved. The channel achieved a relative density of 99.64%, lower and upper surface roughness of 17.4 μm and 13.5 μm, and x and z dimensional errors of 4.12 μm and 3.47 μm, respectively. The best corrosion resistance was obtained at an annealing temperature of 950 °C and a holding time of 3 h, resulting in α and β phase contents of 96.5% and 3.5%, respectively.

Keywords

Multi-objective optimization / Deformation prediction / Shape compensation / Horizontal circular internal flow channel / Laser powder bed fusion (LPBF)

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Funding

Key Technologies Research and Development Program(No.2022YFB4602502)

Shenzhen Science and Technology Innovation Program(No. JCYJ20240813114009013)

Basic and Applied Basic Research Foundation of Guangdong Province(No.2024A1515013258)

Fundamental Research Funds for Central Universities of the Central South University(No. CUGXQN2303)

Rights & permissions

Shanghai University and Periodicals Agency of Shanghai University and Springer-Verlag GmbH Germany, part of Springer Nature

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