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Title: In-situ high-speed X-ray imaging of piezo-driven directed energy deposition additive manufacturing

Abstract

Powder-blown laser additive manufacturing adds flexibility, in terms of locally varying powder materials, to the ability of building components with complex geometry. Although the process is promising, porosity is common in a built component, hence decreasing fatigue life and mechanical strength. The understanding of the physical phenomena during the interaction of a laser beam and powder-blown deposition is limited and requires in-situ monitoring to capture the influences of process parameters on powder flow, absorptivity of laser energy into the substrate, melt pool dynamics and porosity formation. This study introduces a piezo-driven powder deposition system that allows for imaging of individual powder particles that flow into a scanning melt pool. As a result, in-situ high-speed X-ray imaging of the powder-blown additive manufacturing process of Ti-6Al-4V powder particles is the first of its kind and reveals how laser-matter interaction influences powder flow and porosity formation.

Authors:
ORCiD logo [1]; ORCiD logo [2];  [3]; ORCiD logo [3];  [1]; ORCiD logo [3];  [1]
  1. Northwestern Univ., Evanston, IL (United States)
  2. Northwestern Univ., Evanston, IL (United States); Northeastern Univ., Shenyang (People's Republic of China)
  3. Argonne National Lab. (ANL), Lemont, IL (United States)
Publication Date:
Research Org.:
Argonne National Lab. (ANL), Argonne, IL (United States)
Sponsoring Org.:
USDOE Office of Science (SC); National Institute of Standards and Technology (NIST), Center for Hierarchical Materials Design (CHiMaD)
OSTI Identifier:
1494145
Grant/Contract Number:  
AC02-06CH11357
Resource Type:
Journal Article: Accepted Manuscript
Journal Name:
Scientific Reports
Additional Journal Information:
Journal Volume: 9; Journal Issue: 1; Journal ID: ISSN 2045-2322
Publisher:
Nature Publishing Group
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING

Citation Formats

Wolff, Sarah J., Wu, Hao, Parab, Niranjan D., Zhao, Cang, Ehmann, Kornel F., Sun, Tao, and Cao, Jian. In-situ high-speed X-ray imaging of piezo-driven directed energy deposition additive manufacturing. United States: N. p., 2019. Web. doi:10.1038/s41598-018-36678-5.
Wolff, Sarah J., Wu, Hao, Parab, Niranjan D., Zhao, Cang, Ehmann, Kornel F., Sun, Tao, & Cao, Jian. In-situ high-speed X-ray imaging of piezo-driven directed energy deposition additive manufacturing. United States. doi:10.1038/s41598-018-36678-5.
Wolff, Sarah J., Wu, Hao, Parab, Niranjan D., Zhao, Cang, Ehmann, Kornel F., Sun, Tao, and Cao, Jian. Wed . "In-situ high-speed X-ray imaging of piezo-driven directed energy deposition additive manufacturing". United States. doi:10.1038/s41598-018-36678-5. https://www.osti.gov/servlets/purl/1494145.
@article{osti_1494145,
title = {In-situ high-speed X-ray imaging of piezo-driven directed energy deposition additive manufacturing},
author = {Wolff, Sarah J. and Wu, Hao and Parab, Niranjan D. and Zhao, Cang and Ehmann, Kornel F. and Sun, Tao and Cao, Jian},
abstractNote = {Powder-blown laser additive manufacturing adds flexibility, in terms of locally varying powder materials, to the ability of building components with complex geometry. Although the process is promising, porosity is common in a built component, hence decreasing fatigue life and mechanical strength. The understanding of the physical phenomena during the interaction of a laser beam and powder-blown deposition is limited and requires in-situ monitoring to capture the influences of process parameters on powder flow, absorptivity of laser energy into the substrate, melt pool dynamics and porosity formation. This study introduces a piezo-driven powder deposition system that allows for imaging of individual powder particles that flow into a scanning melt pool. As a result, in-situ high-speed X-ray imaging of the powder-blown additive manufacturing process of Ti-6Al-4V powder particles is the first of its kind and reveals how laser-matter interaction influences powder flow and porosity formation.},
doi = {10.1038/s41598-018-36678-5},
journal = {Scientific Reports},
number = 1,
volume = 9,
place = {United States},
year = {Wed Jan 30 00:00:00 EST 2019},
month = {Wed Jan 30 00:00:00 EST 2019}
}

Journal Article:
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Works referenced in this record:

Laser additive manufacturing of metallic components: materials, processes and mechanisms
journal, May 2012