Orthogonal simulation and experimental study on SLM process parameters for micro-sized high dynamic components

Metal Additive Manufacturing (MAM) technology has become an important means of rapid prototyping of special high dynamic complex components. This study employs selective laser melting (SLM) as a technological approach for investigating micro-sized high dynamic components. The parameters that affect SLM process are analysed, mainly including laser power, laser speed, laser diameter, and scan spacing. Based on prior studies, feasible parameter ranges are identified, and an orthogonal experimental design table is established for simulation and experimental co-verification. Range and variance analysis are conducted and the influence ability of each influencing factor is explored from both simulation and experimental aspects. The SLM process model is established using finite element software, taking into account parameters such as residual stress and maximum deformation. The conclusion is drawn that the order of influence of each factor on the preparation of micro-sized high dynamic components is: scan spacing>laser power>laser diameter> laser speed. Samples of components are fabricated and subjected to static testing. The density of the components can reach over 99.15%, and the structural strength can reach 348 MPa, which meet the required standards and confirm the simulation analysis. The results demonstrates that SLM provides a novel manufacturing method for micro-sized high dynamic components.