The International Journal of Advanced Manufacturing Technology (2023) 128:2459–2467

https://doi.org/10.1007/s00170-023-12109-2

ORIGINAL ARTICLE

A novel synchronous scanning strategy in laser powder bed fusion

and effect on mechanical properties of industrial gears
Cemal İrfan Çalışkan1,2

Received: 24 May 2023 / Accepted: 1 August 2023 / Published online: 7 August 2023
© The Author(s), under exclusive licence to Springer-Verlag London Ltd., part of Springer Nature 2023

Abstract
The effect of LPBF process parameter change on production results has been the subject of many studies. In this study, inno-
vative synchronous scanning strategy in LPBF production system and the effect of this scanning strategy on industrial gears
are discussed. The scanning strategy obtained by the synchronous use of hatch distance, stripe width, and layer thickness
parameters constitutes the innovative aspect of the study. In trial productions, it was observed that the traditional melt pool
form changed and the strength increased by 25% in industrial gears produced with this scanning strategy. It is thought that
this synchronous parameter change creates a potential for the production of industrial components with reduced weight. The
scope of the study consists of parameter studies, LPBF production, material laboratory studies, microstructure, and SEM
(scanning electron microscope) examination, and compression test.

Keywords Additive manufacturing (AM) · laser powder bed fusion (LPBF) · Synchronous scanning strategy · Process
parameters · Industrial gear

1 Introduction
Laser powder bed fusion (L-PBF) technology, as the fast-
est developing production system in industrial metal parts
production in recent years [1], has been the subject of many
innovations and researches. The LPBF production system
is known as a layer-based AM technology that allows rapid
prototyping at low cost and is effective in the production of
sophisticated [2] geometries [3] [4] that cannot be produced
[5] with conventional technologies [6] [7]. Process param-
eters that directly affect the production result in AM metal
systems [8], which have been used more intensively after the
1980s, are important in ensuring production standardization.
In LPBF technology, which has been used extensively in
metal industrial productions in recent years and researches
have been concentrated [9], some process parameters such
* Cemal İrfan Çalışkan
cemalirfancaliskan@gmail.com
1
Fatih Sultan Mehmet Vakif University, Aluminium Test,
Training, and Research Center, Halic Campus, Beyoglu,
34445 Istanbul, TR, Turkey
2
Fatih Sultan Mehmet Vakif University, Faculty
of Architecture and Design, Halic Campus, Beyoglu,
34445 Istanbul, TR, Turkey
as laser power [10], contour [11], hatch distance [12], stripe
width [13], and scanning strategy [14] can be mentioned.
The effects of change of process parameters such as micro-
structure [15] [16], physical [17], mechanical [18] [19], and
surface [20] properties, relative density [21], and layer qual-
ity [22] are known [23]. If it is necessary to mention some
leading works done within the scope of process parameters,
in some parameter studies using LPBF, defect formation and
mechanical properties [24] are investigated within the scope
of alloy composition used [25].
LPBF is an AM technology that is used extensively in the
production of innovative designs developed [26] with the
aim of increasing function and efficiency [27] by reducing
weight [28] and offers a wide range of possibilities for the
design, optimization of lightweight, and application-spe-
cific structures [29]. Weight reduction in industrial gears
and increasing performance in various scopes by applying
innovative internal geometries have been the subject of some
studies. The main motivations in these studies are gaining
low vibration ability [30], increasing mechanical strength by
reducing weight [31], the effect of topology optimization on
transmission dynamic [32], and increasing performance with
topology optimization [3] [33]. In addition, some researches
can be mentioned within the scope of innovative design-
oriented industrial gears [34, 35].

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2460 The International Journal of Advanced Manufacturing Technology (2023) 128:2459–2467

Table 2  Material properties of AlSi10Mg [40]

Density (ISO3369) Yield strength (vert.) Yield strength (hor.)
ISO 6892-1 ISO 6892-1

≥ 2.67 g/cm3 230 MPa 270 MPa

Tensile strength (vert.) Tensile strength (hor.) Particle size distri-
ISO 6892-1 ISO 6892-1 bution
460 MPa 450 MPa 25–70 μm
Average defect per- Elongation at break Elongation at break
centage as manufac- (vert.) ISO 6892-1 (hor.) ISO 6892-1
tured
%0.04 %6.3 %10.2

Fig. 1  Novel synchronous scanning strategy within the scope of hatch
distance, stripe width, and layer thickness parameters
In this study, the mechanical strength effect of the scan-
ning strategy created by the synchronized use of hatch dis-
tance, stripe width, and layer thickness parameters, which
are LPBF production process parameters, on gears used in
industrial areas is investigated.
The research carried out in this context consists of two
stages; in the first stage, the microstructure analysis of the
20*20*5 mm test samples produced with the determined
synchronous scanning strategy and standard parameter was
included. In the second stage of the study, the mechanical
strength changes of the industrial gears produced with this
scanning strategy were revealed by the compression test.
The concept of synchronized scanning strategy, which
is the main motivation of the study, refers to the innovative
synchronized use of default production process parameters
developed by the AM technology manufacturer to stand-
ardize production. In this context, the effect of the new
microstructure formed by the synchronous change of cover
distance, strip width, and layer thickness parameters on the
mechanical strength within the scope of industrial gears is
discussed.
2 Experimental
2.1 Synchronous scanning strategy in laser powder
bed fusion
The scope of this work is that the synchronous scanning
strategy developed within the scope of the synchronized use
of hatch distance, stripe width, and layer thickness param-
eters is visualized and shared in Fig. 1. In LPBF production
systems, hatch distance is an important parameter in part
porosity [36]; it represents the offset between the two lines
followed by the laser in the laser layer sintering process [37]
and is shown with the x direction in the transparent scanning
area in Fig. 1. Parameter in the y direction in the same scan-
ning area (Figure 1), with stripe width; the parameter in the
z direction was created by the layer thickness.
The stripe width parameter expresses the path length of
the laser in the layer scanning strategy
[38]. The cubes in Fig. 1 represent the synchronous areas
obtained by using equal distance from each other in the x,
y, and z coordinates of the synchronized scanning strategy.
With the value of 30 μm determined in common in
all three parameters, it is aimed to have a more balanced
thermal distribution in the layers. The production process
parameter sets of the standard production parameter and
synchronous scanning strategy, which will be handled

Table 1  Parameters used in Standard parameter Synchronous scanning strategy

LPBF production
Laser power 370 W 370 W
Laser scan speed 1300 mm/s 1300 mm/s
Hatch distance 0.19 mm 30 μm
Layer thickness 30 μm 30 μm
Beam offset 0.02 mm 0.02 mm
Laser intensity 49.932 J/mm3 316.239 J/mm3
Scanning strategy X-rotated X-Y
Temperature 30 °C ( building platform ) 30 °C ( building platform )
Stripe width 7 mm 30 μm
Laser type Yb (Ytterbium) fiber laser Yb (Ytterbium) fiber laser
Atmosphere Argon Argon

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The International Journal of Advanced Manufacturing Technology (2023) 128:2459–2467 2461

Table 3  Chemical composition Al Si Fe Cu Mn Mg Ni Zn Pb Sn Ti

of AlSi10Mg compliance with
the DIN EN 1706 standard [40] balance % 9.0–11.0 % 0.55 % 0.05 % 0.45 % 0.25–0.45 % 0.05 % 0.10 % 0.05 % 0.05 % 0.15

comparatively within the scope of the study, are shared The laser intensity value change obtained with the use of
in Table 1. Standard production parameters refer to the the following Formula (1) of the data of the process param-
default parameter used in production with AlSi10Mg eter changes is also added to Table 1 [39].
material in EOS M290 production technology. Accord-
P
ingly, nonstandard used parameters are marked with a E= (1)
v∗h∗t
black stripe; the hatch distance, layer thickness, scanning
strategy, and stripe width parameters refer to the process In this formula,
parameters changed within the scope of this study. Since
the scanning strategy visualized in Fig. 1 aims to raise • E = energy
the layers in the same direction, the scanning strategy • P = laser power
parameter in Table 1 is X-Y instead of X-rotated. • v = laser scanning speed

Table 4  Vertical and horizontal vertical cross section horizontal cross section (surface)
section examination under
optical microscope
standard parameter
synchronous scanning strategy

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2462 The International Journal of Advanced Manufacturing Technology (2023) 128:2459–2467

Table 5  CAD (Computer Aided m1 (lattice std.) m2 (std.) m3 (syn.lattice) m4 (syn.)

Design) renders of gear models

Table 6  a.Fabrication of gears a b

in LPBF., b. Completed gear
models

• h = hatch distance
• t = represents the layer thickness
After the parameter determination phase of the study,
20*20*5 mm sample samples in which the synchronous scan-
ning strategy was applied were produced in the LPBF produc-
tion system with AlSi10Mg (Tables 2–3) material, and the
effect of this parameter set on the microstructure was observed.
The microstructure examination made with an optical
microscope is given in Table 4.
Accordingly, it has been observed that the traditional melt
pool form, seen in the cross-section and surface examination of
the samples produced in the standard parameter shared by the
AM production technology as the default, has changed as a full
circle and balloon in the samples produced with the synchronous
scanning strategy. In addition, in the hardness measurements
made from five different points with the samples produced in
20*20*5 mm dimensions, it was observed that the hardness value
of 110 HBW measured in the standard parameter was 133 HBW
in the samples produced with the synchronous scanning strategy.
Production and laboratory studies in which the effect of this new
microstructure form obtained with the first stage of this study
on mechanical strength in case of use in industrial gears will be
investigated will be included in the second part of the research.

Table 7  a.CAD image of compression test apparatus .,b. Test apara- 2.2 Synchronous scanning strategy in industrial
tus compression test gears
a b
The parameters of the scanning strategy obtained in the first
stage of the research are used to be tested in the AM of indus-
trial gears at this stage. The gear form in the DIN 867 standard
determined in this context. The research process was started
by modeling in Catia V5 with m1, m2, m3, and m4 codes. m1
and m3 models express the production of lightened gears with
different LPBF parameters in DIN 867 standard and are geo-
metrically the same. m2 and m4 models are full gear models
in DIN 867 standard, and the m2 model represents the gear

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The International Journal of Advanced Manufacturing Technology (2023) 128:2459–2467
Table 8  Laser scanning
strategies in in-layer patterns
produced with the standard parameter and the m4 model with
the synchronous parameter (Table 5).
The m1 of the models whose CADs are shared in
Table 5 is an industrial gear model manufactured in DIN
867 standard, with a light weight of 12.37 g, with an outer
diameter of 45 mm, an inner diameter of 12 mm and a
thickness of 5 mm, and the number of teeth 28. The m2
model is designed in the same dimensions, and in accord-
ance with the DIN 867 standard, no weight reduction has
been made; it weighs 17.70 grams.
In the comparison between the standard parameter and
the synchronous scanning strategy, each gear production was
added to the study in two different forms as weight-reduced
and solid gears in order to address the effect of parameter
2463
m1
m2
m3
m4
change on geometry. All gear models were produced with
AlSi10Mg material in LPBF system and tested (Table 6).
The m3 and m4 gears are geometrically identical to the m1
and m2 designs; it differs from m1 and m2 within the scope of
the synchronous scanning strategy used in their production.
In the study, besides the comparison of the parameter change
between the m1, m2 group produced with the standard param-
eter and the m3 and m4 group produced with the synchronous
parameter. It also discussed with the effect of geometric vari-
ation between gears m1 and m3 and gears m2 and m4.
The test phase of the gears whose LPBF production process
has been completed, which is shared visually in Table 6, is
passed, and the data obtained by performing the compression
test on the gears fixed to the compression system with the
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2464 The International Journal of Advanced Manufacturing Technology (2023) 128:2459–2467
Table 9  Hatch distance and
stripe width scanning strategies
on gears
hatch distance: 0.19mm
hatch distance: 30 µm
visually shared unit [21] in Table 7 is shared in the results
section.
The pre-production layer inspection images of the syn-
chronous scanning strategy, which constitute the innova-
tive side of this study, are shared in general in Table 8 and
in detail in Table 9. Accordingly, the scanning difference
between the scanning strategy in the m1 and m2 standard
parameters and the m3 and m4 synchronous scanning strate-
gies is shared in Table 8 by enlarging on the sample region
selected on the gear. In the layer analysis, the hatch dis-
tance of 0.19 mm in the m1 and m2 models is clearly seen
(Table 8). In the zoomed images of the m3 and m4 param-
eters, the cube form of the synchronous scanning strategy is
seen in two dimensions in the x and y direction (discussed
in detail in Fig. 1).
Since the images of the general layer scanning strategy
in Table 8 do not fully display the stripe width parameter, in
Table 9 added to the study, the 7-mm stripe width value of the
relevant parameter in m1 and m2 models. The 30-μm value in
the m3 and m4 models is shared in detail.
The compression test results of the gears produced with
the LPBF system and the compression tests of which were
13
m1, m2 (standard process parameter)
stripe width: 7mm
m3, m4 (synchronous scanning strategy)
stripe width: 30 µm
completed in the test setup, and the visuals of the SEM
examination are shared in detail in the Results section and
the results obtained in the Conclusion section.
3 Results and discussion
Within the scope of this research, the innovative scanning
strategy obtained by the synchronized use of LPBF pro-
duction process parameters has increased the mechanical
strength of the designs produced according to the results
of the laboratory studies. Optical microscobe images of the
samples produced by the innovative method obtained by
using the layer thickness, hatch distance, and stripe width
parameters with the same values ​​synchronously show that
the strategy in question changes the material microstructure.
It has been observed that the scanning strategy, which trans-
forms the traditional melt pool form into a balloon shape,
improves the material hardness and strength in the measure-
ments made. Gears in DIN 867 standards were designed in
test sample productions within the scope of investigating
the usability of this scanning strategy in industrial areas,
The International Journal of Advanced Manufacturing Technology (2023) 128:2459–2467 2465

Table 10  SEM images of m1,

m2, m3, m4 gear models
15X surface 40X surface vertical cross section

m1 (lattice std.)
m2 (std.)
m3 (syn.lattice)
m4 (syn.)

the innovative scanning strategy, and the topological gear with compression tests. In this context, it is necessary to
design made for weight reduction which were compara- mention the test and laboratory results.
tively evaluated within the scope of mechanical strength In the gears, the results of the SEM examination focusing
on the deformation zone are shared in Table 10. In addition

Fig. 2  Deformation rates of m1,

m2, m3, and m4 gear models

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2466 The International Journal of Advanced Manufacturing Technology (2023) 128:2459–2467
to the surface examination in 15 × and 40 × dimensions,
vertical cross section images were also preferred in order
to show the deformation styles in the gears in detail and to
determine the fracture types. According to this, especially
in the vertical cross section examination visuals, it is seen
that the brittle fracture type of the m1 and m2 gears produced
with the standard parameter; it is seen that ductile fracture
type occurs in m3 and m4 gears. In this direction, it can be
stated that the synchronized scanning strategy has changed
the brittle fracture type of industrial gears to ductile fracture.
Considering that the deformed and separated parts of the
brittle gears can damage other components in the systems
in which they are used, it is thought that the ductile fracture
feature of the gears with higher strength values will
​​ provide
an advantage in terms of longer operation of the system and
not damaging the components.
Compression test results of four different gears are shared
in graphic form as Fig 2.
According to Fig. 2, plastic deformation begins at 180
MPa and 1.4 mm compression of m1 model produced with
the standard parameter. With these values, it is seen that m1
has the lowest strength value among the four gear models. In
m3, where the same gear model is produced with synchro-
nous scanning parameters, it is seen that plastic deformation
occurs at 2.1 mm compression at 225 MPa. In this case, it can
be stated that the strength increases by 25% with the param-
eter change. According to Fig. 2, it is seen that the plastic
deformation value is 200 MPa in the m2 solid gear model
produced with the standard parameter and this value is 250
MPa, increasing by 25% in the m4 model produced with the
synchronous scanning strategy.
According to the SEM examination and compression test
results, when the m3 model produced with the synchronous
parameter is preferred instead of the m2 model produced
with the standard parameter, it is seen that more strength will
be provided with the lighter gear model. With this compari-
son, it is thought that the innovative synchronous strategy
will provide a solution to the mechanical strength problem
that may occur in design areas such as lattice structures,
which are one of the advantageous aspects of AM.
4 Conclusions
In this study, compression tests and deformation exami-
nations of gears produced in LPBF with two different
parameter sets, standard and synchronous, are included.
The study results, which present a new screening strategy
for LPBF, can be shared as follows:
• According to the graphic results of Fig. 2 in the study,
it is seen that the strength of gears using synchronous
scanning strategy increased by 25%.
13
• The m1 and m3 models added to the study within the
scope of the effect of synchronous parameter change on
geometry are designed to be 43% lighter than m2 and
m4. In this context, it can be stated that the lightweight
gear forms produced with the synchronous scanning
strategy offer higher strength with less material usage.
• In general evaluation, according to the results of SEM
analysis of m1 and m2 models produced with standard
parameters, it can be stated that the brittle fracture style
in these parameters occurs as ductile fracture in m3 and
m4 models.
• In areas where industrial gears are used intensively, the
use of synchronous scanning strategy is important in
order to increase the strength ratios. Synchronous scan-
ning strategy can be considered in the production of
industrial brackets, gears, and components, which are
lightened by topology optimization, in order to balance
the strength properties.
• Topology applications can be discussed within the scope
of the new scanning strategy in innovative studies.
Data availability The author confirm that the data and material sup-
porting the findings of this work are available within the article.
Declarations
Ethical approval The article follows the guidelines of the Committee
on Publication Ethics (COPE) and involves no studies on human or
animal subjects.
Consent to participate Not applicable.
Consent for publication Not applicable.
Competing interests The author declares no competing interests.
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