High-throughput surface characterization to identify porosity defects in additively manufactured 316L stainless steel

Agrawal, Ankur K.; Thoma, Dan J.

doi:10.1016/j.addlet.2022.100093

High-throughput surface characterization to identify porosity defects in additively manufactured 316L stainless steel

Journal Article · Sat Sep 24 00:00:00 EDT 2022 · Additive Manufacturing Letters

DOI:https://doi.org/10.1016/j.addlet.2022.100093· OSTI ID:1895137

Agrawal, Ankur K. ^[1]; ^[2]

Univ. of Wisconsin, Madison, WI (United States); University of Wisconsin-Madison
Univ. of Wisconsin, Madison, WI (United States)

In the present study, a high throughput (HT) methodology is applied to rapidly assess the surface characteristics of 83 additively manufactured 316L stainless steel. The variation in surface roughness (S_a) showed a good correlation with a dimensionless number (π) and provided direct linkages to the internal porosity defects. Lack-of-fusion regime relates to high surface roughness (S_a > 5 µm), low dimensionless number (π < 61), and the presence of cavities in between the melt pool tracks. Balling regime correlates to high surface roughness (S_a > 5 µm), intermediate dimensionless number (61 < π < 146), and non-uniform melt pool track width. Keyhole regime shows low surface roughness (S_a < 5 µm), high dimensionless number (π > 146), and a curved melt pool track. This approach accelerates the process parameter discovery and minimizes the porosity defects for the LPBF process. The impact of the defects on the as-processed tensile mechanical properties demonstrates that samples with porosity exhibit up to 10% less tensile strength and 30% less ductility than optimal samples.

View Accepted Manuscript (DOE)

Research Organization:: Georgia Institute of Technology, Atlanta, GA (United States)

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

Grant/Contract Number:: NA0003921

OSTI ID:: 1895137

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

References (25)

Balling behavior of stainless steel and nickel powder during selective laser melting process Li, Ruidi; Liu, Jinhui; Shi, Yusheng The International Journal of Advanced Manufacturing Technology, Vol. 59, Issue 9-12 https://doi.org/10.1007/s00170-011-3566-1	journal	August 2011
Strengthening mechanisms in directed energy deposited austenitic stainless steel Smith, Thale R.; Sugar, Joshua D.; San Marchi, Chris Acta Materialia, Vol. 164 https://doi.org/10.1016/j.actamat.2018.11.021	journal	February 2019
Assessing printability maps in additive manufacturing of metal alloys Johnson, Luke; Mahmoudi, Mohamad; Zhang, Bing Acta Materialia, Vol. 176 https://doi.org/10.1016/j.actamat.2019.07.005	journal	September 2019
Defects and anomalies in powder bed fusion metal additive manufacturing Mostafaei, Amir; Zhao, Cang; He, Yining Current Opinion in Solid State and Materials Science, Vol. 26, Issue 2 https://doi.org/10.1016/j.cossms.2021.100974	journal	April 2022
Predictive process mapping for laser powder bed fusion: A review of existing analytical solutions Agrawal, Ankur K.; Rankouhi, Behzad; Thoma, Dan J. Current Opinion in Solid State and Materials Science, Vol. 26, Issue 6 https://doi.org/10.1016/j.cossms.2022.101024	journal	December 2022
Mitigation of lack of fusion defects in powder bed fusion additive manufacturing Mukherjee, T.; DebRoy, T. Journal of Manufacturing Processes, Vol. 36 https://doi.org/10.1016/j.jmapro.2018.10.028	journal	December 2018
High throughput mechanical testing platform and application in metal additive manufacturing and process optimization Huang, Ke; Kain, Chris; Diaz-Vallejo, Nathalia Journal of Manufacturing Processes, Vol. 66 https://doi.org/10.1016/j.jmapro.2021.04.027	journal	June 2021
Single track formation in selective laser melting of metal powders Yadroitsev, I.; Gusarov, A.; Yadroitsava, I. Journal of Materials Processing Technology, Vol. 210, Issue 12 https://doi.org/10.1016/j.jmatprotec.2010.05.010	journal	September 2010
Energy input effect on morphology and microstructure of selective laser melting single track from metallic powder Yadroitsev, I.; Krakhmalev, P.; Yadroitsava, I. Journal of Materials Processing Technology, Vol. 213, Issue 4 https://doi.org/10.1016/j.jmatprotec.2012.11.014	journal	April 2013
Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing King, Wayne E.; Barth, Holly D.; Castillo, Victor M. Journal of Materials Processing Technology, Vol. 214, Issue 12 https://doi.org/10.1016/j.jmatprotec.2014.06.005	journal	December 2014
Scaling laws for the laser welding process in keyhole mode Fabbro, Remy Journal of Materials Processing Technology, Vol. 264 https://doi.org/10.1016/j.jmatprotec.2018.09.027	journal	February 2019
Experimental investigation of selective laser melting parameters for higher surface quality and microhardness properties: taguchi and super ranking concept approaches Sheshadri, Rohith; Nagaraj, Mohan; Lakshmikanthan, Avinash Journal of Materials Research and Technology, Vol. 14 https://doi.org/10.1016/j.jmrt.2021.07.144	journal	September 2021
Design of an interpretable Convolutional Neural Network for stress concentration prediction in rough surfaces Kantzos, Christopher; Lao, Jacky; Rollett, Anthony Materials Characterization, Vol. 158 https://doi.org/10.1016/j.matchar.2019.109961	journal	December 2019
Effect of laser power on defect, texture, and microstructure of a laser powder bed fusion processed 316L stainless steel Choo, Hahn; Sham, Kin-Ling; Bohling, John Materials & Design, Vol. 164 https://doi.org/10.1016/j.matdes.2018.12.006	journal	February 2019
Effects of defects on mechanical properties in metal additive manufacturing: A review focusing on X-ray tomography insights du Plessis, Anton; Yadroitsava, Ina; Yadroitsev, Igor Materials & Design, Vol. 187 https://doi.org/10.1016/j.matdes.2019.108385	journal	February 2020
Strengthening control in laser powder bed fusion of austenitic stainless steels via grain boundary engineering Sabzi, Hossein Eskandari; Hernandez-Nava, Everth; Li, Xiao-Hui Materials & Design, Vol. 212 https://doi.org/10.1016/j.matdes.2021.110246	journal	December 2021
A dimensionless number for predicting universal processing parameter boundaries in metal powder bed additive manufacturing Rankouhi, Behzad; Agrawal, Ankur Kumar; Pfefferkorn, Frank E. Manufacturing Letters, Vol. 27 https://doi.org/10.1016/j.mfglet.2020.12.002	journal	January 2021
Correlation between process parameters, microstructure and properties of 316 L stainless steel processed by selective laser melting Kurzynowski, Tomasz; Gruber, Konrad; Stopyra, Wojciech Materials Science and Engineering: A, Vol. 718 https://doi.org/10.1016/j.msea.2018.01.103	journal	March 2018
Identification and characterization of spatter particles and their effect on surface roughness, density and mechanical response of 17-4 PH stainless steel laser powder-bed fusion parts Ali, Usman; Esmaeilizadeh, Reza; Ahmed, Farid Materials Science and Engineering: A, Vol. 756 https://doi.org/10.1016/j.msea.2019.04.026	journal	May 2019
High-throughput experimentation for microstructural design in additively manufactured 316L stainless steel Agrawal, Ankur Kumar; Meric de Bellefon, Gabriel; Thoma, Dan Materials Science and Engineering: A, Vol. 793 https://doi.org/10.1016/j.msea.2020.139841	journal	August 2020
Additive manufacturing of metallic components – Process, structure and properties DebRoy, T.; Wei, H. L.; Zuback, J. S. Progress in Materials Science, Vol. 92 https://doi.org/10.1016/j.pmatsci.2017.10.001	journal	March 2018
Metallurgy, mechanistic models and machine learning in metal printing DebRoy, T.; Mukherjee, T.; Wei, H. L. Nature Reviews Materials, Vol. 6, Issue 1 https://doi.org/10.1038/s41578-020-00236-1	journal	October 2020
Review of selective laser melting: Materials and applications Yap, C. Y.; Chua, C. K.; Dong, Z. L. Applied Physics Reviews, Vol. 2, Issue 4 https://doi.org/10.1063/1.4935926	journal	December 2015
Theoretical and experimental study on surface roughness of 316L stainless steel metal parts obtained through selective laser melting Wang, Di; Liu, Yang; Yang, Yongqiang Rapid Prototyping Journal, Vol. 22, Issue 4 https://doi.org/10.1108/RPJ-06-2015-0078	journal	June 2016
Keyhole threshold and morphology in laser melting revealed by ultrahigh-speed x-ray imaging Cunningham, Ross; Zhao, Cang; Parab, Niranjan Science, Vol. 363, Issue 6429 https://doi.org/10.1126/science.aav4687	journal	February 2019

Similar Records

Predictive process mapping for laser powder bed fusion: A review of existing analytical solutions

Journal Article · Tue Jul 26 00:00:00 EDT 2022 · Current Opinion in Solid State and Materials Science · OSTI ID:1895149

Melt Pool characteristics on surface roughness and printability of 316L stainless steel in laser powder bed fusion

Journal Article · Thu Jul 25 00:00:00 EDT 2024 · Rapid Prototyping Journal · OSTI ID:2582669

Related Subjects

316L stainless steel
36 MATERIALS SCIENCE
Additive manufacturing
High-throughput
Laser powder bed fusion
Surface roughness

High-throughput surface characterization to identify porosity defects in additively manufactured 316L stainless steel

Citation Formats

References (25)

Similar Records

Related Subjects