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Title: In-situ characterization and quantification of melt pool variation under constant input energy density in laser powder bed fusion additive manufacturing process

Abstract

Size and shape of a melt pool play a critical role in determining the microstructure in additively manufactured metals. However, it is very challenging to directly characterize the size and shape of the melt pool beneath the surface of the melt pool during the additive manufacturing process. Here, we report the direct observation and quantification of melt pool variation during the laser powder bed fusion (LPBF) additive manufacturing process under constant input energy density by in-situ high-speed high-energy x-ray imaging. We show that the melt pool can undergo different melting regimes and both the melt pool dimension and melt pool volume can have orders-of-magnitude change under a constant input energy density. Our analysis shows that the significant melt pool variation cannot be solely explained by the energy dissipation rate. We found that energy absorption changes significantly under a constant input energy density, which is another important cause of melt pool variation. Our further analysis reveals that the significant change in energy absorption originates from the separate roles of laser power and scan speed in depression zone development. The results reported here are important for understanding the laser powder bed fusion additive manufacturing process and guiding the development of better metricsmore » for processing parameter design.« less

Authors:
; ; ; ; ; ; ; ; ; ;
Publication Date:
Research Org.:
Argonne National Laboratory (ANL), Argonne, IL (United States). Advanced Photon Source (APS); Kansas City National Security Campus, MO (United States)
Sponsoring Org.:
USDOE Laboratory Directed Research and Development (LDRD) Program; USDOE Office of Science (SC); National Science Foundation (NSF)
OSTI Identifier:
1547155
Alternate Identifier(s):
OSTI ID: 1608324
Grant/Contract Number:  
AC02-06CH11357; NA0002839
Resource Type:
Journal Article: Published Article
Journal Name:
Additive Manufacturing
Additional Journal Information:
Journal Name: Additive Manufacturing Journal Volume: 28 Journal Issue: C; Journal ID: ISSN 2214-8604
Publisher:
Elsevier
Country of Publication:
Netherlands
Language:
English
Subject:
36 MATERIALS SCIENCE; Additive manufacturing; Energy absorption; Laser powder bed fusion; Melt pool; X-ray imaging

Citation Formats

Guo, Qilin, Zhao, Cang, Qu, Minglei, Xiong, Lianghua, Escano, Luis I., Hojjatzadeh, S. Mohammad H., Parab, Niranjan D., Fezzaa, Kamel, Everhart, Wes, Sun, Tao, and Chen, Lianyi. In-situ characterization and quantification of melt pool variation under constant input energy density in laser powder bed fusion additive manufacturing process. Netherlands: N. p., 2019. Web. doi:10.1016/j.addma.2019.04.021.
Guo, Qilin, Zhao, Cang, Qu, Minglei, Xiong, Lianghua, Escano, Luis I., Hojjatzadeh, S. Mohammad H., Parab, Niranjan D., Fezzaa, Kamel, Everhart, Wes, Sun, Tao, & Chen, Lianyi. In-situ characterization and quantification of melt pool variation under constant input energy density in laser powder bed fusion additive manufacturing process. Netherlands. https://doi.org/10.1016/j.addma.2019.04.021
Guo, Qilin, Zhao, Cang, Qu, Minglei, Xiong, Lianghua, Escano, Luis I., Hojjatzadeh, S. Mohammad H., Parab, Niranjan D., Fezzaa, Kamel, Everhart, Wes, Sun, Tao, and Chen, Lianyi. 2019. "In-situ characterization and quantification of melt pool variation under constant input energy density in laser powder bed fusion additive manufacturing process". Netherlands. https://doi.org/10.1016/j.addma.2019.04.021.
@article{osti_1547155,
title = {In-situ characterization and quantification of melt pool variation under constant input energy density in laser powder bed fusion additive manufacturing process},
author = {Guo, Qilin and Zhao, Cang and Qu, Minglei and Xiong, Lianghua and Escano, Luis I. and Hojjatzadeh, S. Mohammad H. and Parab, Niranjan D. and Fezzaa, Kamel and Everhart, Wes and Sun, Tao and Chen, Lianyi},
abstractNote = {Size and shape of a melt pool play a critical role in determining the microstructure in additively manufactured metals. However, it is very challenging to directly characterize the size and shape of the melt pool beneath the surface of the melt pool during the additive manufacturing process. Here, we report the direct observation and quantification of melt pool variation during the laser powder bed fusion (LPBF) additive manufacturing process under constant input energy density by in-situ high-speed high-energy x-ray imaging. We show that the melt pool can undergo different melting regimes and both the melt pool dimension and melt pool volume can have orders-of-magnitude change under a constant input energy density. Our analysis shows that the significant melt pool variation cannot be solely explained by the energy dissipation rate. We found that energy absorption changes significantly under a constant input energy density, which is another important cause of melt pool variation. Our further analysis reveals that the significant change in energy absorption originates from the separate roles of laser power and scan speed in depression zone development. The results reported here are important for understanding the laser powder bed fusion additive manufacturing process and guiding the development of better metrics for processing parameter design.},
doi = {10.1016/j.addma.2019.04.021},
url = {https://www.osti.gov/biblio/1547155}, journal = {Additive Manufacturing},
issn = {2214-8604},
number = C,
volume = 28,
place = {Netherlands},
year = {Sat Jun 01 00:00:00 EDT 2019},
month = {Sat Jun 01 00:00:00 EDT 2019}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record at https://doi.org/10.1016/j.addma.2019.04.021

Citation Metrics:
Cited by: 125 works
Citation information provided by
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