• 한국분말재료학회지
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• 제28권2호
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• pp.120-126
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• 2021

In this study, AlSi10Mg alloy powders are synthesized using gas atomization and sieving processes for powder bed fusion (PBF) additive manufacturing. The effect of nozzle diameter (ø = 4.0, 4.5, 5.0 and 8.0 mm) on the gas atomization and sieving size on the properties of the prepared powder are investigated. As the nozzle diameter decreases, the size of the manufactured powder decreases, and the uniformity of the particle size distribution improves. Therefore, the ø 4.0 mm nozzle diameter yields powder with superior properties. Spherically shaped powders can be prepared at a scale suitable for the PBF process with a particle size distribution of 10-45 ㎛. The Hausner ratio value of the powder is measured to be 1.24. In addition, the yield fraction of the powder prepared in this study is 26.6%, which is higher than the previously reported value of 10-15%. These results indicate that the nozzle diameter and the post-sieve process simultaneously influence the shape of the prepared powder as well as the satellite powder on its surface.

• 한국정밀공학회지
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• 제32권9호
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• pp.773-779
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• 2015

The laser Powder Bed Fusion (PBF) system is currently recognized as a leading process. Due to the various materials employed such as thermoplastic, metal and ceramic composite powder, the application's use extends to machinery, automobiles, and medical devices. The PBF system's surface quality of prototypes and processing time are significantly affected by several parameters such as laser power, laser beam size, heat temperature and laminate thickness. In order to develop a more elaborate and rapid system, this study developed a new PBF system and sintering process. It contains a 3-axis dynamic focusing scanner system that maintains a uniform laser beam size throughout the system unlike the $f{\theta}$ lens. In this study, experiments were performed to evaluate the effects of various laser scanning parameters and fabricating parameters on the fusion process, in addition to fabricating various 3D objects using a PA-12 starting material.

• 한국기계가공학회지
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• 제21권7호
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• pp.10-20
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• 2022

Recently, metal additive manufacturing (AM) is being investigated as a new manufacturing technology. In metal AM, powder bed fusion (PBF) is a promising technology that can be used to manufacture small and complex metallic components by selectively fusing each powder layer using an energy source such as laser or an electron beam. PBF includes selective laser melting (SLM) and electron beam melting (EBM). SLM uses high power-density laser to melt and fuse metal powders. EBM is similar to SLM but melts metals using an electron beam. When these processes are applied, the mechanical properties and microstructures change due to the many parameters involved. Therefore, this study is conducted to investigate the effects of the parameters on the mechanical properties and microstructures such that the processes can be performed more economically and efficiently.

• 한국분말재료학회지
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• 제27권6호
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• pp.509-519
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• 2020

A well-established characterization method is required in powder bed fusion (PBF) metal additive manufacturing, where metal powder is used. The characterization methods from the traditional powder metallurgy process are still being used. However, it is necessary to develop advanced methods of property evaluation with the advances in additive manufacturing technology. In this article, the characterization methods of powders for metal PBF are reviewed, and the recent research trends are introduced. Standardization status and specifications for metal powder for the PBF process which published by the ISO, ASTM, and MPIF are also covered. The establishment of powder characterization methods are expected to contribute to the metal powder industry and the advancement of additive manufacturing technology through the creation of related databases.

• 한국분말재료학회지
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• 제27권1호
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• pp.44-51
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• 2020

Powder characteristics, such as density, size, shape, thermal properties, and surface area, are of significant importance in the powder bed fusion (PBF) process. The powder required is exclusive for an efficient PBF process. In this study, the particle size distribution suitable for the powder bed fusion process was derived by modeling the PBF product using simulation software (GeoDict). The modeling was carried out by layering sintered powder with a large particle size distribution, with 50 ㎛ being the largest particle size. The results of the simulation showed that the porosity decreased when the mean particle size of the powder was reduced or the standard deviation increased. The particle size distribution of prepared titanium powder by the atomization process was also studied. This study is expected to offer direction for studies related to powder production for additive manufacturing.

• 한국인터넷방송통신학회논문지
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• 제19권5호
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• pp.239-244
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• 2019

기존의 주조 방식은 긴 제작 시간과 많은 비용이 소모되며, 즉각적인 디자인 수정이 불가능하여 다변화하는 현대사회에 대응하기 어려웠다. 때문에 주조 산업은 새로운 대안이 필요했으며 그 중 하나가 적층 제조 기술과의 접목이다. 적층제조기술에는 7가지가 있으나 본 논문에서는 PBF를 활용한 중자 제작을 살펴보려고 한다. 현재의 적층 제조 기술 장비들은 대부분 외산 장비들로 기능 활용과 서비스의 제약이 따르고 있어서 장비의 국산화가 필요하였고 장비의 개발과 함께 기술 활용의 내용을 담았다. 각 장에서는 PBF의 장비 개발 단계 및 소재 적용과 변수 설정에 대해서 서술하고 있으며, 최종적으로 기술을 활용한 산업용 중자 개발의 성공과 특성에 대한 정보를 보여주고 있다.

• 한국산학기술학회논문지
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• 제19권10호
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• pp.346-351
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• 2018

금속 3D 프린팅 기술은 레이저 빔의 초점에 금속분말을 주입하는 방식에 따라 대표적으로 PBF(Powder Bed Fusion)방식과 DED(Direct Energy Deposition)방식으로 나뉜다. DED 방식은 금속 분말 도포와 동시에 레이저를 조사하여 3차원 구조물을 제작하는 금속 3D 프린팅 기술이고, PBF 방식은 일정 높이로 3차원 그래픽을 슬라이싱 한 후 한 층씩 금속 분말을 적층하여 레이저를 이용해 3차원 구조물을 제조하는 방식이다. DED 방식을 사용하면 레이저 클래딩, 금속 용접 등에는 강점을 가지지만 3D 형상을 제작할 경우 밀도가 낮아지는 문제점이 발생한다. DED 방식에서의 구조체 밀도 문제를 해결하기 위해 PBF 방식을 도입하면 상대적으로 밀도가 높은 3차원 구조물을 제작하는데 용이하다. 본 논문에서는 갈바노 스캐너와 광섬유로 전송되는 Nd:YAG 레이저 빔을 이용한 약 $30{\mu}m$ 크기의 스테인리스 강 분말을 이용하는 PBF 방식의 3차원 프린터를 제작하고, 이를 이용하여 얇은 금속 구조물을 제작하였다. 또한 레이저의 조사 횟수, 출력, 초점 크기, 스캐닝 속도에 따른 선폭의 최적조건을 찾았으며, 그 결과 최적 조건은 레이저 조사 횟수 2회, 출력 30 W, 초점 크기 $28.7{\mu}m$, 스캐닝 속도 200 mm/s에서 최소 선폭은 약 $85.3{\mu}m$로 측정되었다.

• 한국정밀공학회지
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• 제32권9호
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• pp.765-771
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• 2015

In an Additive Manufacturing (AM) system emplying the Powder Bed Fusion (PBF) system, polyamide-12 powder is currently recognized as the general material used. The Polyamide-12 powder's properties include an average particle size of 58 $58{\mu}m$, a density of 0.59 g/cm3, and melting point of $184^{\circ}C$, and can also be to used coat materials for metal powder. For this reason, the sintering process is similar to the polymer powder and polymer coated metal powder process, except during the post-process. The polyamide-12 powder has some disadvantages such as its high cost and the fact that it can only be used for the provided equipment from the maker. Therefore, this study aims to perform the applicability of new material, polymer and polymer coated metal, to the PBF system.

• 한국분말재료학회지
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• 제30권2호
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• pp.140-145
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• 2023

Although the Ti-6Al-4V alloy has been used in the aircraft industry owing to its excellent mechanical properties and low density, the low formability of the alloy hinders broadening its applications. Recently, laser-powder bed fusion (L-PBF) has become a novel process for overcoming the limitations of the alloy (i.e., low formability), owing to the high degree of design freedom for the geometry of products having outstanding performance used in high-tech applications. In this study, to investigate the effect of bulk shape on the microstructure and mechanical properties of L-PBFed Ti-6Al-4V alloys, two types of samples are fabricated using L-PBF: thick and thin samples. The thick sample exhibits lower strength and higher ductility than the thin sample owing to the larger grain size and lower residual dislocation density of the thick sample because of the heat input during the L-PBF process.

• 한국분말재료학회지
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• 제29권1호
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• pp.14-21
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• 2022

In the powder bed fusion (PBF) process, a 3D shape is formed by the continuous stacking of very fine powder layers using computer-aided design (CAD) modeling data, following which laser irradiation can be used to fuse the layers forming the desired product. In this method, the main process parameters for manufacturing the desired 3D products are laser power, laser speed, powder form, powder size, laminated thickness, and laser diameter. Stainless steel (STS) 316L exhibits excellent strength at high temperatures, and is also corrosion resistant. Due to this, it is widely used in various additive manufacturing processes, and in the production of corrosion-resistant components with complicated shapes. In this study, rectangular specimens have been manufactured using STS 316L powder via the PBF process. Further, the effect of heat treatment at 800 ℃ on the microstructure and hardness has been investigated.