PBF-LB of large-area magnesium WE43 structures surface-enhanced by plasma electrolytic oxidation

verfasst von: Arvid Abel, Anutsek Sharma, Hannes Holländer, Dawn Zheng, Nicole Emminghaus, Anna Buling, Jörg Hermsdorf, Jörg Zerrer, Stefan Kaierle
Abstract: Due to the improved understanding of the industry, additive manufacturing processes are becoming increasingly accepted for fabricating complex lightweight components. The focus of the magnesium research is primarily on small implant structures. Due to challenges in the manufacturing process and oxidation behavior, large structures for lightweight components are mainly fabricated with titanium. This paper expands the scope of the laser-based powder bed fusion (PBF-LB) of larger-area magnesium parts with surface enhancement using the Ultraceramic® by the plasma electrolytic oxidation (PEO). For this purpose, the PBF-LB process development for cylindric structures with a diameter of 31 mm is carried out. The processing strategies are adapted for a crack and porosity free process. To mitigate the inherent oxidation of the biodegradable WE43 and reduce the surface wear in tribologically challenging applications, the additively manufactured magnesium is modified by the Ultraceramic®. The thickness of the ceramic surface could be tailored between 10 and 40 µm, while enclosing adhering powder particles of the PBF. Electrochemical impedance spectroscopy showed an increased resistance to corrosion by an increased modulus |Z_0.01| by a factor of 658. The tribological behavior was characterized in pin-on-disc experiments and showed a decrease of surface wear down to 7.9 × 10^–6 mm³/N·m up to a Hertzian pressure of 720 MPa tested by a tungsten carbide ball. Therefore, the synthesis of the PBF-LB of large-area magnesium parts and the PEO of the Ultraceramic^® enables lightweight components for challenging oxidative and tribological conditions in real world applications.
Organisationseinheit(en): Institut für Transport- und Automatisierungstechnik
Externe Organisation(en): Laser Zentrum Hannover e.V. (LZH)
Eloxalwerk Ludwigsburg Helmut Zerrer GmbH (ELB)
Typ: Artikel
Journal: Progress in Additive Manufacturing
Band: 9
Seiten: 683-694
Anzahl der Seiten: 12
ISSN: 2363-9512
Publikationsdatum: 06.2024
Publikationsstatus: Veröffentlicht
Peer-reviewed: Ja
ASJC Scopus Sachgebiete: Wirtschaftsingenieurwesen und Fertigungstechnik
Elektronische Version(en): https://doi.org/10.1007/s40964-024-00664-3 (Zugang: Offen)

BibTeX

@article{ff3848fe319647d3a991abd0810f149d,
title = "PBF-LB of large-area magnesium WE43 structures surface-enhanced by plasma electrolytic oxidation",
abstract = "Due to the improved understanding of the industry, additive manufacturing processes are becoming increasingly accepted for fabricating complex lightweight components. The focus of the magnesium research is primarily on small implant structures. Due to challenges in the manufacturing process and oxidation behavior, large structures for lightweight components are mainly fabricated with titanium. This paper expands the scope of the laser-based powder bed fusion (PBF-LB) of larger-area magnesium parts with surface enhancement using the Ultraceramic{\textregistered} by the plasma electrolytic oxidation (PEO). For this purpose, the PBF-LB process development for cylindric structures with a diameter of 31 mm is carried out. The processing strategies are adapted for a crack and porosity free process. To mitigate the inherent oxidation of the biodegradable WE43 and reduce the surface wear in tribologically challenging applications, the additively manufactured magnesium is modified by the Ultraceramic{\textregistered}. The thickness of the ceramic surface could be tailored between 10 and 40 µm, while enclosing adhering powder particles of the PBF. Electrochemical impedance spectroscopy showed an increased resistance to corrosion by an increased modulus |Z0.01| by a factor of 658. The tribological behavior was characterized in pin-on-disc experiments and showed a decrease of surface wear down to 7.9 × 10–6 mm3/N·m up to a Hertzian pressure of 720 MPa tested by a tungsten carbide ball. Therefore, the synthesis of the PBF-LB of large-area magnesium parts and the PEO of the Ultraceramic{\textregistered} enables lightweight components for challenging oxidative and tribological conditions in real world applications.",
keywords = "Laser-based powder bed fusion, Magnesium, Plasma electrolytic oxidation, Ultraceramic, WE43",
author = "Arvid Abel and Anutsek Sharma and Hannes Holl{\"a}nder and Dawn Zheng and Nicole Emminghaus and Anna Buling and J{\"o}rg Hermsdorf and J{\"o}rg Zerrer and Stefan Kaierle",
note = "Publisher Copyright: {\textcopyright} The Author(s) 2024.",
year = "2024",
month = jun,
doi = "10.1007/s40964-024-00664-3",
language = "English",
volume = "9",
pages = "683--694",
journal = "Progress in Additive Manufacturing",
issn = "2363-9512",
publisher = "Springer Verlag",
number = "3",
}