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Title: Denudation of metal powder layers in laser powder bed fusion processes

Abstract

Understanding laser interaction with metal powder beds is critical in predicting optimum processing regimes in laser powder bed fusion additive manufacturing of metals. In this work, we study the denudation of metal powders that is observed near the laser scan path as a function of laser parameters and ambient gas pressure. We show that the observed depletion of metal powder particles in the zone immediately surrounding the solidified track is due to a competition between outward metal vapor flux directed away from the laser spot and entrainment of powder particles in a shear flow of gas driven by a metal vapor jet at the melt track. Between atmospheric pressure and ~10 Torr of Ar gas, the denuded zone width increases with decreasing ambient gas pressure and is dominated by entrainment from inward gas flow. The denuded zone then decreases from 10 to 2.2 Torr reaching a minimum before increasing again from 2.2 to 0.5 Torr where metal vapor flux and expansion from the melt pool dominates. In addition, the dynamics of the denudation process were captured using high-speed imaging, revealing that the particle movement is a complex interplay among melt pool geometry, metal vapor flow, and ambient gas pressure. Themore » experimental results are rationalized through finite element simulations of the melt track formation and resulting vapor flow patterns. The results presented here represent new insights to denudation and melt track formation that can be important for the prediction and minimization of void defects and surface roughness in additively manufactured metal components.« less

Authors:
ORCiD logo; ; ; ; ;
Publication Date:
Research Org.:
Lawrence Livermore National Lab., Livermore, CA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1253936
Alternate Identifier(s):
OSTI ID: 1281668
Report Number(s):
LLNL-JRNL-680585
Journal ID: ISSN 1359-6454; S135964541630355X; PII: S135964541630355X
Grant/Contract Number:  
AC52-07NA27344; 15-ERD-037
Resource Type:
Published Article
Journal Name:
Acta Materialia
Additional Journal Information:
Journal Name: Acta Materialia Journal Volume: 114 Journal Issue: C; Journal ID: ISSN 1359-6454
Publisher:
Elsevier
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 42 ENGINEERING; selective laser melting; powder bed fusion; surface structure; defects; fluid dynamics; finite element modeling; high speed imaging

Citation Formats

Matthews, Manyalibo J., Guss, Gabe, Khairallah, Saad A., Rubenchik, Alexander M., Depond, Philip J., and King, Wayne E. Denudation of metal powder layers in laser powder bed fusion processes. United States: N. p., 2016. Web. https://doi.org/10.1016/j.actamat.2016.05.017.
Matthews, Manyalibo J., Guss, Gabe, Khairallah, Saad A., Rubenchik, Alexander M., Depond, Philip J., & King, Wayne E. Denudation of metal powder layers in laser powder bed fusion processes. United States. https://doi.org/10.1016/j.actamat.2016.05.017
Matthews, Manyalibo J., Guss, Gabe, Khairallah, Saad A., Rubenchik, Alexander M., Depond, Philip J., and King, Wayne E. Mon . "Denudation of metal powder layers in laser powder bed fusion processes". United States. https://doi.org/10.1016/j.actamat.2016.05.017.
@article{osti_1253936,
title = {Denudation of metal powder layers in laser powder bed fusion processes},
author = {Matthews, Manyalibo J. and Guss, Gabe and Khairallah, Saad A. and Rubenchik, Alexander M. and Depond, Philip J. and King, Wayne E.},
abstractNote = {Understanding laser interaction with metal powder beds is critical in predicting optimum processing regimes in laser powder bed fusion additive manufacturing of metals. In this work, we study the denudation of metal powders that is observed near the laser scan path as a function of laser parameters and ambient gas pressure. We show that the observed depletion of metal powder particles in the zone immediately surrounding the solidified track is due to a competition between outward metal vapor flux directed away from the laser spot and entrainment of powder particles in a shear flow of gas driven by a metal vapor jet at the melt track. Between atmospheric pressure and ~10 Torr of Ar gas, the denuded zone width increases with decreasing ambient gas pressure and is dominated by entrainment from inward gas flow. The denuded zone then decreases from 10 to 2.2 Torr reaching a minimum before increasing again from 2.2 to 0.5 Torr where metal vapor flux and expansion from the melt pool dominates. In addition, the dynamics of the denudation process were captured using high-speed imaging, revealing that the particle movement is a complex interplay among melt pool geometry, metal vapor flow, and ambient gas pressure. The experimental results are rationalized through finite element simulations of the melt track formation and resulting vapor flow patterns. The results presented here represent new insights to denudation and melt track formation that can be important for the prediction and minimization of void defects and surface roughness in additively manufactured metal components.},
doi = {10.1016/j.actamat.2016.05.017},
journal = {Acta Materialia},
number = C,
volume = 114,
place = {United States},
year = {2016},
month = {8}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record
https://doi.org/10.1016/j.actamat.2016.05.017

Citation Metrics:
Cited by: 35 works
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