Transient dynamics of powder spattering in laser powder bed fusion additive manufacturing process revealed by in-situ high-speed high-energy x-ray imaging

Guo, Qilin; Zhao, Cang; Escano, Luis I.; Young, Zachary; Xiong, Lianghua; Fezzaa, Kamel; Everhart, Wes; Brown, Ben; Sun, Tao; Chen, Lianyi

doi:10.1016/j.actamat.2018.03.036

Transient dynamics of powder spattering in laser powder bed fusion additive manufacturing process revealed by in-situ high-speed high-energy x-ray imaging

Journal Article · Mon Mar 26 00:00:00 EDT 2018 · Acta Materialia

DOI:https://doi.org/10.1016/j.actamat.2018.03.036· OSTI ID:1477838

Guo, Qilin ^[1]; ^[2]; Escano, Luis I. ^[1]; Young, Zachary ^[1]; ^[1]; Fezzaa, Kamel ^[2]; ^[3]; Brown, Ben ^[3]; ^[2]; Chen, Lianyi ^[1]

Missouri Univ. of Science and Technology, Rolla, MO (United States)
Argonne National Lab. (ANL), Argonne, IL (United States)
Dept. of Energy's Kansas City National Security Campus, Kansas City, MO (United States)

Powder spattering is a major cause of defect formation and quality uncertainty in the laser powder bed fusion (LPBF) additive manufacturing (AM) process. It is very difficult to investigate this with either conventional characterization tools or modeling and simulation. The detailed dynamics of powder spattering in the LPBF are still not fully understood. Here, we report insights into the transient dynamics of powder spattering in the LPBF process that were observed with in-situ high-speed high-energy x-ray imaging. Powder motion dynamics, as functions of time, environment pressure, and location, are presented. The moving speed, acceleration, and driving force of powder motion that are induced by metal vapor jet/plume and argon gas flow are quantified. A schematic map showing the dynamics and mechanisms of powder motion during the LPBF process as functions of time and pressure is constructed. In conclusion, potential ways to mitigate powder spattering during the LPBF process are discussed and proposed, based on the revealed powder motion dynamics and mechanisms.

View Accepted Manuscript (DOE)

Research Organization:: Argonne National Lab. (ANL), Argonne, IL (United States)

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES) (SC-22); Honeywell Federal Manufacturing and Technologies, LLC

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 1477838

Alternate ID(s):: OSTI ID: 1548513
OSTI ID: 22744582

Journal Information:: Acta Materialia, Journal Name: Acta Materialia Journal Issue: C Vol. 151; ISSN 1359-6454

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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