Laser-Induced Keyhole Defect Dynamics during Metal Additive Manufacturing

Kiss, Andrew M.; Fong, Anthony Y.; Calta, Nicholas P.; Thampy, Vivek; Martin, Aiden A.; Depond, Philip J.; Wang, Jenny; Matthews, Manyalibo J.; Ott, Ryan T.; Tassone, Christopher J.; Stone, Kevin H.; Kramer, Matthew J.; van Buuren, Anthony; Toney, Michael F.; Nelson Weker, Johanna

doi:10.1002/adem.201900455

Title: Laser-Induced Keyhole Defect Dynamics during Metal Additive Manufacturing

Journal Article · Tue Jul 16 00:00:00 EDT 2019 · Advanced Engineering Materials

DOI:https://doi.org/10.1002/adem.201900455· OSTI ID:1560679

^[1]; Fong, Anthony Y. ^[1]; Calta, Nicholas P. ^[2]; Thampy, Vivek ^[1]; Martin, Aiden A. ^[2]; Depond, Philip J. ^[2]; Wang, Jenny ^[2]; Matthews, Manyalibo J. ^[2]; Ott, Ryan T. ^[3]; Tassone, Christopher J. ^[1]; Stone, Kevin H. ^[1]; Kramer, Matthew J. ^[3]; van Buuren, Anthony ^[2]; Toney, Michael F. ^[1]; Nelson Weker, Johanna ^[1]

SLAC National Accelerator Lab., Menlo Park, CA (United States)
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Ames Lab. and Iowa State Univ., Ames, IA (United States)

Laser powder bed fusion (LPBF) metal additive manufacturing provides distinct advantages for aerospace and biomedical applications. However, widespread industrial adoption is limited by a lack of confidence in part properties driven by an incomplete understanding of how unique process parameters relate to defect formation and ultimately mechanical properties. To address that gap, high-speed X-ray imaging is used to probe subsurface melt pool dynamics and void-formation mechanisms inaccessible to other monitoring approaches. This technique directly observes the depth and dynamic behavior of the vapor depression, also known as the keyhole depression, which is formed by recoil pressure from laser-driven metal vaporization. Also, vapor bubble formation and motion due to melt pool currents is observed, including instances of bubbles splitting before solidification into clusters of smaller voids while the material rapidly cools. Other phenomena include bubbles being formed from and then recaptured by the vapor depression, leaving no voids in the final part. Such events complicate attempts to identify defect formation using surface-sensitive process-monitoring tools. Finally, once the void defects form, they cannot be repaired by simple laser scans, without introducing new defects, thus emphasizing the importance of understanding processing parameters to develop robust defect-mitigation strategies based on experimentally validated models.

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Research Organization:: SLAC National Accelerator Laboratory (SLAC), Menlo Park, CA (United States); Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES); USDOE National Nuclear Security Administration (NNSA); USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office

Grant/Contract Number:: AC02-07CH11358; AC02-76SF00515; SC0012704; AC52-07NA27344

OSTI ID:: 1560679

Alternate ID(s):: OSTI ID: 1557328; OSTI ID: 1560982

Report Number(s):: LLNL-JRNL-748807; TRN: US2000556

Journal Information:: Advanced Engineering Materials, Vol. 21, Issue 10; ISSN 1438-1656

Publisher:: WileyCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 40 works

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