Layer Thickness Inconsistency
Layer thickness inconsistency is a local variation in powder layer thickness caused by uneven wiper or rake movements. This leads to insufficient fusion and impairs part integrity.
Physical-Chemical Mechanism of Action
Layer thickness inconsistency occurs when the recoater or squeegee movements are uneven during powder deposition. This leads to varying layer thicknesses in different areas of the deposit. In areas with thinner layers, the metal is less well fused, which can cause incomplete fusion and possibly porosity.
Metallurgical Relevance & Welding Risks
Layer thickness inconsistency affects the internal integrity of the part. It can lead to incomplete fusion and porosity, which reduces the strength and toughness of the weldment. In extreme cases, this can lead to cracks or hot cracks, endangering the part.
Workshop Practice & Action Guidelines
To minimize layer thickness inconsistency, adjust the recoater or squeegee movements to be as uniform as possible. This can be achieved by carefully calibrating the machine parameters. Regular checks of the powder deposit for layer thickness uniformity are also important. If inconsistency is detected, recalibrate the machine or adjust the recoater movements.