Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing

Ly, Sonny; Rubenchik, Alexander M.; Khairallah, Saad A.; Guss, Gabe; Matthews, Manyalibo J.

doi:10.1038/s41598-017-04237-z

Title: Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing

Journal Article · Thu Jun 22 00:00:00 EDT 2017 · Scientific Reports

DOI:https://doi.org/10.1038/s41598-017-04237-z· OSTI ID:1395471

Ly, Sonny ^[1]; Rubenchik, Alexander M. ^[2]; Khairallah, Saad A. ^[3]; Guss, Gabe ^[4]; Matthews, Manyalibo J. ^[1]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States). Materials Science Division, Physical and Life Sciences Directorate
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States). Laser Science and Systems Engineering, NIF and Photon Sciences Directorate
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States). Computational Engineering, Engineering Directorate
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States). Laser Systems Engineering Operations, Engineering Directorate

The results of detailed experiments and finite element modeling of metal micro-droplet motion associated with metal additive manufacturing (AM) processes are presented. Ultra high speed imaging of melt pool dynamics reveals that the dominant mechanism leading to micro-droplet ejection in a laser powder bed fusion AM is not from laser induced recoil pressure as is widely believed and found in laser welding processes, but rather from vapor driven entrainment of micro-particles by an ambient gas flow. The physics of droplet ejection under strong evaporative flow is described using simulations of the laser powder bed interactions to elucidate the experimental results. Hydrodynamic drag analysis is used to augment the single phase flow model and explain the entrainment phenomenon for 316 L stainless steel and Ti-6Al-4V powder layers. The relevance of vapor driven entrainment of metal micro-particles to similar fluid dynamic studies in other fields of science will be discussed.

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Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 1395471

Journal Information:: Scientific Reports, Vol. 7, Issue 1; ISSN 2045-2322

Publisher:: Nature Publishing GroupCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 259 works

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