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Powder Spreading Dynamics and Process Optimization at a Heterogeneous Interface for Z-Direction Multi-Material Laser Powder Bed Fusion.

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Title: Powder Spreading Dynamics and Process Optimization at a Heterogeneous Interface for Z-Direction Multi-Material Laser Powder Bed Fusion.
Authors: Xiang, Zhaowei1 (AUTHOR) hflhfllbj@163.com, Ma, Shuai1 (AUTHOR), Han, Fulin1 (AUTHOR), Wang, Ju1 (AUTHOR)
Source: Materials (1996-1944). May2026, Vol. 19 Issue 9, p1762. 21p.
Subjects: Powder bed fusion, Process optimization, Discrete element method, Composite material manufacturing, Powders, Copper-zirconium alloys, Stainless steel
Abstract: This paper investigates the powder spreading process in a Z-direction multi-material fabrication system utilizing a blade. Focusing on 316L stainless steel and CuCrZr, a discrete element model was developed to simulate powder spreading at the heterogeneous material interface. The effects of spreading speed and theoretical layer thickness on the resulting powder bed quality were systematically examined. The results reveal that during spreading over a heterogeneous bed, the underlying powder exhibits an unsteady "forward-surging and rearward-suppressing" motion pattern, with inter-particle force chains displaying significant spatiotemporal fluctuations. Increasing the spreading speed exacerbates the disturbance and removal of the underlying powder, leading to a reduction in the deposited mass of CuCrZr and a deterioration in its distribution uniformity. Conversely, increasing the layer thickness effectively mitigates the mechanical disturbance of the underlying powder by the blade, significantly enhancing both the deposited mass of CuCrZr and its distribution uniformity. Further investigation demonstrates that employing a higher spreading speed in combination with a larger layer thickness can achieve a favorable powder bed quality while maintaining high spreading efficiency, thereby enabling a synergistic optimization of productivity and bed quality. This work elucidates the mesoscopic dynamic mechanisms governing the powder spreading process at Z-direction heterogeneous interfaces and provides a theoretical foundation for process optimization in multi-material laser powder bed fusion. [ABSTRACT FROM AUTHOR]
Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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Header DbId: egs
DbLabel: Engineering Source
An: 193715568
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PubTypeId: academicJournal
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  Label: Title
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  Data: Powder Spreading Dynamics and Process Optimization at a Heterogeneous Interface for Z-Direction Multi-Material Laser Powder Bed Fusion.
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  Data: <searchLink fieldCode="AR" term="%22Xiang%2C+Zhaowei%22">Xiang, Zhaowei</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> hflhfllbj@163.com</i><br /><searchLink fieldCode="AR" term="%22Ma%2C+Shuai%22">Ma, Shuai</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Han%2C+Fulin%22">Han, Fulin</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Wang%2C+Ju%22">Wang, Ju</searchLink><relatesTo>1</relatesTo> (AUTHOR)
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  Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. May2026, Vol. 19 Issue 9, p1762. 21p.
– Name: Subject
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  Data: <searchLink fieldCode="DE" term="%22Powder+bed+fusion%22">Powder bed fusion</searchLink><br /><searchLink fieldCode="DE" term="%22Process+optimization%22">Process optimization</searchLink><br /><searchLink fieldCode="DE" term="%22Discrete+element+method%22">Discrete element method</searchLink><br /><searchLink fieldCode="DE" term="%22Composite+material+manufacturing%22">Composite material manufacturing</searchLink><br /><searchLink fieldCode="DE" term="%22Powders%22">Powders</searchLink><br /><searchLink fieldCode="DE" term="%22Copper-zirconium+alloys%22">Copper-zirconium alloys</searchLink><br /><searchLink fieldCode="DE" term="%22Stainless+steel%22">Stainless steel</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: This paper investigates the powder spreading process in a Z-direction multi-material fabrication system utilizing a blade. Focusing on 316L stainless steel and CuCrZr, a discrete element model was developed to simulate powder spreading at the heterogeneous material interface. The effects of spreading speed and theoretical layer thickness on the resulting powder bed quality were systematically examined. The results reveal that during spreading over a heterogeneous bed, the underlying powder exhibits an unsteady "forward-surging and rearward-suppressing" motion pattern, with inter-particle force chains displaying significant spatiotemporal fluctuations. Increasing the spreading speed exacerbates the disturbance and removal of the underlying powder, leading to a reduction in the deposited mass of CuCrZr and a deterioration in its distribution uniformity. Conversely, increasing the layer thickness effectively mitigates the mechanical disturbance of the underlying powder by the blade, significantly enhancing both the deposited mass of CuCrZr and its distribution uniformity. Further investigation demonstrates that employing a higher spreading speed in combination with a larger layer thickness can achieve a favorable powder bed quality while maintaining high spreading efficiency, thereby enabling a synergistic optimization of productivity and bed quality. This work elucidates the mesoscopic dynamic mechanisms governing the powder spreading process at Z-direction heterogeneous interfaces and provides a theoretical foundation for process optimization in multi-material laser powder bed fusion. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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RecordInfo BibRecord:
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    Identifiers:
      – Type: doi
        Value: 10.3390/ma19091762
    Languages:
      – Code: eng
        Text: English
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      Pagination:
        PageCount: 21
        StartPage: 1762
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      – SubjectFull: Powder bed fusion
        Type: general
      – SubjectFull: Process optimization
        Type: general
      – SubjectFull: Discrete element method
        Type: general
      – SubjectFull: Composite material manufacturing
        Type: general
      – SubjectFull: Powders
        Type: general
      – SubjectFull: Copper-zirconium alloys
        Type: general
      – SubjectFull: Stainless steel
        Type: general
    Titles:
      – TitleFull: Powder Spreading Dynamics and Process Optimization at a Heterogeneous Interface for Z-Direction Multi-Material Laser Powder Bed Fusion.
        Type: main
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          Name:
            NameFull: Xiang, Zhaowei
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            NameFull: Ma, Shuai
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            NameFull: Han, Fulin
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            NameFull: Wang, Ju
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            – D: 01
              M: 05
              Text: May2026
              Type: published
              Y: 2026
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              Value: 19
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              Value: 9
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            – TitleFull: Materials (1996-1944)
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