Additive manufacturing, such as selective laser melting (SLM), can be used to manufacture cellular parts. In this study, cellular coupons of maraging steels are prepared through SLM by varying hatch distance. Air flow and permeability of porous maraging steel blocks are obtained for samples of different thickness based on the Darcy equation. By reducing hatch distance from 0.75 to 0.4 mm, the permeability decreases from 1.664 × 10-6 mm2 to 0.991 × 10-6 mm2 for 4 mm thick coupons. In addition, by increasing the thickness from 2 to 8 mm, the permeability increases from 0.741 × 10-6 mm2 to 1.345 × 10-6 mm2 at 16.2 J/mm3 energy density and 0.14 MPa inlet pressure. Simulation using ANSYS-Fluent is conducted to observe the pressure difference across the porous coupons and is compared with the experimental results. Surface artifacts and the actual morphology of scan lines can cause the simulated permeability to deviate from the experimental values. The measured permeability of maraging steel coupons is regression fit with both energy density and size of samples which provide a design guideline of porous mold inserts for industry applications such as injection molding.
Keywords: additive manufacturing; cellular parts; injection molding; mold inserts; permeability; porosity.