Operando visualization of porous metal additive manufacturing with foaming agents through high-speed x-ray imaging

Tian, Chenxi; Bustillos, Jenniffer; Wakai, Akane; Gabourel, Ashlee; Clark, Samuel J.; Fezzaa, Kamel; Moridi, Atieh

doi:10.1016/j.addma.2024.104505

Operando visualization of porous metal additive manufacturing with foaming agents through high-speed x-ray imaging

Journal Article · Mon Oct 21 00:00:00 EDT 2024 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2024.104505· OSTI ID:2569860

^[1]; Bustillos, Jenniffer ^[1]; Wakai, Akane ^[1]; ^[1]; ^[2]; Fezzaa, Kamel ^[2]; ^[1]

Cornell Univ., Ithaca, NY (United States)
Argonne National Laboratory (ANL), Argonne, IL (United States)

Porous metals find extensive applications in soundproofing, filtration, catalysis, and energy-absorbing structures, thanks to their unique internal pore structure and high specific strength. In recent years, there has been an increasing interest in fabricating porous metals using additive manufacturing (AM), leveraging its unique advantages, including improved design freedom, spatial material control, and cost-effective small-batch production. In this study, we conducted pioneering operando visualization of AM porous metal using a laser powder bed fusion (L-PBF) setup combined with a high-speed synchrotron x-ray imaging system. Single track printing experiments using Ti6Al4V (Ti64) combined with titanium hydride (TiH₂) and sodium carbonate (Na₂CO₃) as foaming agents, with varying mixing ratios were performed under different processing conditions. Here. the results elucidate the dynamic development of porosity formation. The average pore size is significantly influenced by the particle size of foaming agents when pore coalescence is absent. For all foaming agent content tested in the current study, the number of pores is found to be more sensitive to changes in laser power than in laser scanning speed. Increasing linear energy density (increasing laser power or reducing laser scanning speed) promotes the foaming agent activation thereby porosity formation. However, high linear energy density skews pore distribution towards the surface despite forming deeper melt pools. In addition, the impact of additional factors including foaming agent's laser absorptivity and decomposition kinetics with respect to AM time scales should be carefully considered to avoid ineffective activation of foaming agents during the AM of porous metals.

View Accepted Manuscript (DOE)

Research Organization:: Argonne National Laboratory (ANL), Argonne, IL (United States). Advanced Photon Source (APS)

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities (SUF); National Science Foundation (NSF); US Department of the Navy, Office of Naval Research (ONR)

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 2569860

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Vol. 94; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Operando visualization of porous metal additive manufacturing with foaming agents through high-speed x-ray imaging

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