Direct mechanistic connection between acoustic signals and melt pool morphology during laser powder bed fusion

Sun, Yuchen; Gorgannejad, Sanam; Martin, Aiden; Nicolino, Jenny; Strantza, Maria; Forien, Jean-Baptiste; Thampy, Vivek; Liu, Sen; Quan, Peiyu; Tassone, Christopher J.; Matthews, Manyalibo J.; Calta, Nicholas P.

doi:10.1063/5.0205663

Direct mechanistic connection between acoustic signals and melt pool morphology during laser powder bed fusion

Journal Article · Mon Jul 15 00:00:00 EDT 2024 · Applied Physics Letters

DOI:https://doi.org/10.1063/5.0205663· OSTI ID:2440329

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Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
SLAC National Accelerator Laboratory (SLAC), Menlo Park, CA (United States)

Various nondestructive diagnostic techniques have been proposed for in situ process monitoring of laser powder bed fusion (LPBF), including melt pool pyrometry, whole-layer optical imaging, acoustic emission, atomic emission spectroscopy, high speed melt pool imaging, and thermionic emission. Correlations between these in situ monitoring signals and defect formation have been demonstrated with acoustic signals having been shown to predict pore formation with especially high confidence in recent machine learning studies. Here, in this work, time-resolved acoustic data are collected in both the conduction and keyhole welding regimes of LPBF-processed Ti-6Al-4V alloy. A non-dimensionalized Strouhal number analysis, used in whistle aeroacoustics, is applied to demonstrate that the acoustic signals recorded in the keyhole regimes can be directly associated with the vapor depression morphology. This mechanistic understanding developed from whistle aeroacoustics shows that acoustic monitoring during the LPBF process can provide a direct probe into the vapor depression dynamics and defect occurrence, especially in the keyhole regimes relevant to printing and defect formation.

View Accepted Manuscript (DOE)

Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States); SLAC National Accelerator Laboratory (SLAC), Menlo Park, CA (United States)

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

Grant/Contract Number:: AC52-07NA27344; AC02-76SF00515

OSTI ID:: 2440329

Report Number(s):: LLNL--JRNL-857714; 1087848

Journal Information:: Applied Physics Letters, Journal Name: Applied Physics Letters Journal Issue: 3 Vol. 125; ISSN 0003-6951

Publisher:: American Institute of Physics (AIP)Copyright Statement

Country of Publication:: United States

Language:: English

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