Application of Direct Metal Laser Sintering for the Electrode Production and Study of Associated Process Parameters

The manufacturing sector is greatly influenced by the application of modern metal removal processes for the production of complex part geometries, the processes being non-conventional, versatile and more precise. Selective laser sintering is an additive manufacturing process which produces three-dimensional objects by fusing the powdered metal layer-by-layer in the presence of laser light. This work focuses on the manufacturing of electrodes by Direct Metal Laser Sintering and evaluating the influence of process parameters on the output responses under consideration. Laser power, scan speed, laser spot size, layer thickness, porosity and hatch spacing are the process parameters affecting the electrode production process. Sintering depth, energy density, relative density and ultimate tensile strength are the output responses. The experimental analysis examines the impact of the process parameters on sintering depth for the powdered Aluminium Alloy 6061. Optimised parameters are found to be 120W laser power, 285mm/s scanning speed, 15% porosity, 0.2mm laser spot size and 2.04mm layer thickness. Taguchi method is one of the techniques to obtain optimised electrode production by Direct Metal Laser Sintering.