Effect of Blade Geometry on Powder Spreading Behavior for High-Speed PBF
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Additive manufacturing (AM) technologies have attracted considerable attention because they enable the fabrication of three-dimensional parts with complex geometries. Among the various AM techniques, powder bed fusion (PBF) has become a central method for metal AM. In PBF, parts are fabricated by repeatedly spreading metal powder layers and selectively fusing them. Recently, increasing the number of heat sources has improved build speed; the time required for powder bed formation has become a significant share of the total process time. However, increasing the blade translation speed for high-speed building decreases powder bed quality. In this study, we investigate the effects of blade geometry, i.e., blade-platform angle θblade, on powder bed characteristics by discrete element method (DEM) simulations. DEM simulations were performed with Large-scale Atomic/Molecular Massively Parallel Simulator (LAMMPS). Ti-6Al-4V powder for the laser PBF (D50 = 38.7 µm) was used, and cohesive parameters were calibrated through powder-drop experiments based on the measured angle of repose. DEM simulations revealed that a low blade angle results in a higher-quality powder bed under high-speed powder spreading conditions. A detailed analysis of particle behavior during the powder bed formation simulation revealed that when θblade was 90°, some particles flowed upward along the blade. On the other hand, when θblade was 20°, no particles flowed upward along the blade, but instead moved toward the gap. This suggests that reducing the blade angle limits upward particle flow along the blade during the rake, thereby increasing the particle supply to the gap and the coverage area ratio. Experiments using an LPBF machine (EOS M290) confirmed that reducing the blade angle improved surface roughness and build density, even at high blade speeds (500 mm/s).
