Detecting keyhole porosity and monitoring process signatures in additive manufacturing: an in situ pyrometry and ex situ X-ray radiography correlation

Forien, J; Calta, N; DePond, P; Guss, G; Roehling, T; Matthews, M

doi:10.1016/j.addma.2020.101336

Detecting keyhole porosity and monitoring process signatures in additive manufacturing: an in situ pyrometry and ex situ X-ray radiography correlation

Journal Article · Wed May 20 00:00:00 EDT 2020 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2020.101336· OSTI ID:1635089

Forien, J ^[1]; Calta, N ^[1]; DePond, P ^[1]; Guss, G ^[1]; Roehling, T ^[1]; Matthews, M ^[1]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

Creation of pores and defects during laser powder bed fusion (LPBF) can lead to poor mechanical properties and thus must be minimized. Post-build inspection is required to ensure the printed parts contain acceptably low defect concentrations. These inspections are time consuming and costly, especially for large or complex parts. As a potential solution, in situ process monitoring can be used to detect the creation of defects, characterize local material behavior and predict expected component properties. However, the precise relationship between pore creation and in situ process monitoring still needs to be understood. In this work, high-speed infrared diode-based pyrometry and high-speed optical imaging signals were used to monitor LPBF printing of 446 stainless steel 316 L single tracks with varying laser power and velocity. Results indicate an increase in pyrometer signal and melt pool dimensions with increasing laser power and decreasing velocity in agreement with previous work. In addition, careful analysis of pyrometer signal reveals a distinct signature of the conduction-to-keyhole mode transition which was confirmed by metallography. Critically, pore defect initiation as characterized by ex situ X-ray radiography was correlated with in situ thermal monitoring signals to derive the probability of defect creation. Our results show that, in principle, a probabilistic prediction of pore formation can be achieved based on in situ high-speed pyrometry monitoring of the LPBF melt pool.

View Accepted Manuscript (DOE)

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

Sponsoring Organization:: USDOE; USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 1635089

Alternate ID(s):: OSTI ID: 1809812

Report Number(s):: LLNL-JRNL--782115; 975613

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: na Vol. vol. 35; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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