Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging

Young, Zachary A.; Coday, Meelap M.; Guo, Qilin; Qu, Minglei; Hojjatzadeh, S. Mohammad H.; Escano, Luis I.; Fezzaa, Kamel; Sun, Tao; Chen, Lianyi

doi:10.3390/ma15020530

Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging

Journal Article · Tue Jan 11 00:00:00 EST 2022 · Materials

DOI:https://doi.org/10.3390/ma15020530· OSTI ID:1894937

Young, Zachary A. ^[1]; Coday, Meelap M. ^[1]; ^[2]; ^[2]; ^[2]; Escano, Luis I. ^[2]; ^[3]; Sun, Tao ^[4]; ^[1]

Missouri Univ. of Science and Technology, Rolla, MO (United States); Univ. of Wisconsin, Madison, WI (United States)
Univ. of Wisconsin, Madison, WI (United States)
Argonne National Lab. (ANL), Argonne, IL (United States). Advanced Photon Source (APS)
Univ. of Virginia, Charlottesville, VA (United States)

Selective laser melting (SLM) additive manufacturing (AM) exhibits uncertainties, where variations in build quality are present despite utilizing the same optimized processing parameters. In this work, we identify the sources of uncertainty in SLM process by in-situ characterization of SLM dynamics induced by small variations in processing parameters. We show that variations in the laser beam size, laser power, laser scan speed, and powder layer thickness result in significant variations in the depression zone, melt pool, and spatter behavior. On average, a small deviation of only ~5% from the optimized/reference laser processing parameter resulted in a ~10% or greater change in the depression zone and melt pool geometries. For spatter dynamics, small variation (10 μm, 11%) of the laser beam size could lead to over 40% change in the overall volume of the spatter generated. The responses of the SLM dynamics to small variations of processing parameters revealed in this work are useful for understanding the process uncertainties in the SLM process.

View Accepted Manuscript (DOE)

Research Organization:: Argonne National Laboratory (ANL)

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities Division

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 1894937

Journal Information:: Materials, Journal Name: Materials Journal Issue: 2 Vol. 15; ISSN 1996-1944

Publisher:: MDPICopyright Statement

Country of Publication:: United States

Language:: English

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Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging

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