Nanoparticle-enabled increase of energy efficiency during laser metal additive manufacturing

Qu, Minglei; Guo, Qilin; Escano, Luis Izet; Nabaa, Ali; Fezzaa, Kamel; Chen, Lianyi

doi:10.1016/j.addma.2022.103242

Nanoparticle-enabled increase of energy efficiency during laser metal additive manufacturing

Journal Article · Sat Oct 22 00:00:00 EDT 2022 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2022.103242· OSTI ID:2280941

Qu, Minglei ^[1]; ^[1]; Escano, Luis Izet ^[1]; ^[1]; Fezzaa, Kamel ^[2]; ^[1]

University of Wisconsin, Madison, WI (United States)
Argonne National Laboratory (ANL), Argonne, IL (United States). X-ray Science Division

The low energy efficiency of the laser metal additive manufacturing (AM) process is a potential sustainability concern for large-scale industrial production. Explicit investigation of the energy efficiency for laser melting requires the direct characterization of melt pool dimension and vapor depression, which is very difficult due to the opaque nature of the molten metal. Here we report the direct observation and quantification of effects of the TiC nanoparticles on the vapor depression and melt pool formation during laser powder bed fusion (LPBF) of Al6061 by in-situ high-speed high-energy x-ray imaging. Based on the quantification results, we calculated the laser melting energy efficiency (defined here as the ratio of the energy needed to melt the material to the energy delivered by the laser beam) with and without TiC nanoparticles during LPBF of Al6061. Here the results show that adding TiC nanoparticles into Al6061 leads to a significant increase of laser melting energy efficiency (114% increase on average, 521% increase under 312 W laser power, 0.4 m/s scan speed). Systematic property measurement, simulation, and x-ray imaging studies enable us, for the first time, to identify that three mechanisms work together to enhance the laser melting energy efficiency: (1) adding TiC nanoparticles increases the absorptivity; (2) adding TiC nanoparticles decreases the thermal conductivity, and (3) adding TiC nanoparticles enables the initiation of vapor depression and multiple reflection at lower laser power (i.e., lowers the laser power threshold for keyholing). The method and mechanisms of using TiC nanoparticles to increase the laser melting energy efficiency during LPBF of Al6061 we reported here may guide the development of feedstock materials for more energy efficient laser metal AM.

View Accepted Manuscript (DOE)

Research Organization:: Argonne National Laboratory (ANL), Argonne, IL (United States)

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

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 2280941

Alternate ID(s):: OSTI ID: 1898225

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Vol. 60; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Related Subjects

36 MATERIALS SCIENCE
additive manufacturing
energy efficiency
keyhole
laser powder bed fusion
melt pool
metal matrix nanocomposites
x-ray imaging

Nanoparticle-enabled increase of energy efficiency during laser metal additive manufacturing

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