Melt-Pool Dynamics and Microstructure of Mg Alloy WE43 under Laser Powder Bed Fusion Additive Manufacturing Conditions

Soderlind, Julie; Martin, Aiden A.; Calta, Nicholas P.; DePond, Philip J.; Wang, Jenny; Vrancken, Bey; Schäublin, Robin E.; Basu, Indranil; Thampy, Vivek; Fong, Anthony Y.; Kiss, Andrew M.; Berry, Joel M.; Perron, Aurélien; Nelson Weker, Johanna; Stone, Kevin H.; Tassone, Christopher J.; Toney, Michael F.; Van Buuren, Anthony; Löffler, Jörg F.; Risbud, Subhash H.; Matthews, Manyalibo J.

doi:10.3390/cryst12101437

Title: Melt-Pool Dynamics and Microstructure of Mg Alloy WE43 under Laser Powder Bed Fusion Additive Manufacturing Conditions

Journal Article · Wed Oct 12 00:00:00 EDT 2022 · Crystals

DOI:https://doi.org/10.3390/cryst12101437· OSTI ID:1892088

Soderlind, Julie;

;

; Wang, Jenny;

;

; Basu, Indranil; Thampy, Vivek; Fong, Anthony Y.; Kiss, Andrew M.; Berry, Joel M.; Perron, Aurélien;

; Stone, Kevin H.; Tassone, Christopher J.; Toney, Michael F.; Van Buuren, Anthony;

;

Magnesium-based alloy WE43 is a state-of-the-art bioresorbable metallic implant material. There is a need for implants with both complex geometries to match the mechanical properties of bone and refined microstructure for controlled resorption. Additive manufacturing (AM) using laser powder bed fusion (LPBF) presents a viable fabrication method for implant applications, as it offers near-net-shape geometrical control, allows for geometry customization based on an individual patient, and fast cooling rates to achieve a refined microstructure. In this study, the laser–alloy interaction is investigated over a range of LPBF-relevant processing conditions to reveal melt-pool dynamics, pore formation, and the microstructure of laser-melted WE43. In situ X-ray imaging reveals distinct laser-induced vapor depression morphology regimes, with minimal pore formation at laser-scan speeds greater than 500 mm/s. Optical and electron microscopy of cross-sectioned laser tracks reveal three distinct microstructural regimes that can be controlled by adjusting laser-scan parameters: columnar, dendritic, and banded microstructures. These regimes are consistent with those predicted by the analytic solidification theory for conduction-mode welding, but not for keyhole-mode tracks. The results provide insight into the fundamental laser–material interactions of the WE43 alloy under AM-processing conditions and are critical for the successful implementation of LPBF-produced WE43 parts in biomedical applications.

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Research Organization:: SLAC National Accelerator Laboratory (SLAC), Menlo Park, CA (United States). Stanford Synchrotron Radiation Lightsource (SSRL); Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE); USDOE National Nuclear Security Administration (NNSA); USDOE Office of Science (SC), Basic Energy Sciences (BES); USDOE Laboratory Directed Research and Development (LDRD) Program; University of California

Grant/Contract Number:: 18-SI-003; CPA Agreement Numbers 32035, 32037, and 32038; AC52-07NA27344; AC02-76SF00515; LGF-17-476556

OSTI ID:: 1892088

Alternate ID(s):: OSTI ID: 1987687; OSTI ID: 1991621; OSTI ID: 2007275

Report Number(s):: LLNL-JRNL-811193; CRYSBC; PII: cryst12101437

Journal Information:: Crystals, Journal Name: Crystals Vol. 12 Journal Issue: 10; ISSN 2073-4352

Publisher:: MDPI AGCopyright Statement

Country of Publication:: Germany

Language:: English

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36 MATERIALS SCIENCE
additive manufacturing
magnesium
laser powder bed fusion
X-ray imaging
electron microscopy
microstructure

Title: Melt-Pool Dynamics and Microstructure of Mg Alloy WE43 under Laser Powder Bed Fusion Additive Manufacturing Conditions

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