Mitigating keyhole pore formation by nanoparticles during laser powder bed fusion additive manufacturing

Qu, Minglei; Guo, Qilin; Escano, Luis I.; Clark, Samuel J.; Fezzaa, Kamel; Chen, Lianyi

doi:10.1016/j.addlet.2022.100068

Mitigating keyhole pore formation by nanoparticles during laser powder bed fusion additive manufacturing

Journal Article · Fri Jun 17 00:00:00 EDT 2022 · Additive Manufacturing Letters

DOI:https://doi.org/10.1016/j.addlet.2022.100068· OSTI ID:1889812

Qu, Minglei ^[1]; Guo, Qilin ^[1]; Escano, Luis I. ^[1]; Clark, Samuel J. ^[2]; Fezzaa, Kamel ^[2]; ^[1]

Univ. of Wisconsin, Madison, WI (United States)
Argonne National Lab. (ANL), Lemont, IL (United States)

Keyhole pore formation is one of the most detrimental subsurface defects in the laser metal additive manufacturing process. However, effective ways to mitigate keyhole pore formation beyond tuning laser processing conditions during keyhole mode laser melting are still lacking. Here we report a novel approach to mitigate keyhole pore formation during laser powder bed fusion (LPBF) process by using stable nanoparticles. The critical keyhole depth for keyhole pore generation (i.e., the largest keyhole depth without keyhole pore formation) during LPBF of Al6061 increases from 246 µm to 454 µm (85% increase) after adding TiC nanoparticles. In-depth x-ray imaging studies and thermo-fluid dynamics simulation enable us to identify that two mechanisms work together to mitigate keyhole pore generation: (1) adding nanoparticles prevents the keyhole from collapsing by increasing the liquid viscosity to impede the protrusion development; (2) adding nanoparticles slows down the keyhole pore movement by increasing the liquid viscosity, resulting in the recapturing of the pore by the keyhole. We further demonstrate that adding TiC nanoparticles can also eliminate the keyhole fluctuation induced keyhole pore during LPBF of Al6061. Our research provides a potential way to mitigate keyhole pore formation for defect lean metal additive manufacturing.

View Accepted Manuscript (DOE)

Research Organization:: Argonne National Lab. (ANL), Argonne, IL (United States). Advanced Photon Source (APS)

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES); National Science Foundation (NSF); University of Wisconsin-Madison

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 1889812

Journal Information:: Additive Manufacturing Letters, Journal Name: Additive Manufacturing Letters Vol. 3; ISSN 2772-3690

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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