Modulating laser intensity profile ellipticity for microstructural control during metal additive manufacturing

Roehling, Tien T.; Wu, Sheldon S. Q.; Khairallah, Saad A.; Roehling, John D.; Soezeri, S. Stefan; Crumb, Michael F.; Matthews, Manyalibo J.

doi:10.1016/j.actamat.2017.02.025

Title: Modulating laser intensity profile ellipticity for microstructural control during metal additive manufacturing

Abstract

Additively manufactured (AM) metals are often highly textured, containing large columnar grains that initiate epitaxially under steep temperature gradients and rapid solidification conditions. These unique microstructures partially account for the massive property disparity existing between AM and conventionally processed alloys. Although equiaxed grains are desirable for isotropic mechanical behavior, the columnar-to-equiaxed transition remains difficult to predict for conventional solidification processes, and much more so for AM. In this study, the effects of laser intensity profile ellipticity on melt track macrostructures and microstructures were studied in 316L stainless steel. Experimental results were supported by temperature gradients and melt velocities simulated using the ALE3D multi-physics code. As a general trend, columnar grains preferentially formed with increasing laser power and scan speed for all beam profiles. However, when conduction mode laser heating occurs, scan parameters that result in coarse columnar microstructures using Gaussian profiles produce equiaxed or mixed equiaxed-columnar microstructures using elliptical profiles. Furthermore, by modulating spatial laser intensity profiles on the fly, site-specific microstructures and properties can be directly engineered into additively manufactured parts.

Authors:

; Wu, Sheldon S. Q.; Khairallah, Saad A.; Roehling, John D.; Soezeri, S. Stefan; Crumb, Michael F.; Matthews, Manyalibo J.

Publication Date:: Sat Apr 01 00:00:00 EDT 2017

Research Org.:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Org.:: USDOE Office of Science (SC), Office of Workforce Development for Teachers & Scientists (WDTS); USDOE

OSTI Identifier:: 1393688

Alternate Identifier(s):: OSTI ID: 1357374

Report Number(s):: LLNL-JRNL-713205
Journal ID: ISSN 1359-6454; S1359645417301167; PII: S1359645417301167

Grant/Contract Number:: AC52-07NA27344; 15-ERD-037; 15-ERD-006

Resource Type:: Published Article

Journal Name:: Acta Materialia

Additional Journal Information:: Journal Name: Acta Materialia Journal Volume: 128 Journal Issue: C; Journal ID: ISSN 1359-6454

Publisher:: Elsevier

Country of Publication:: United States

Language:: English

Subject:: 36 MATERIALS SCIENCE; 42 ENGINEERING; additive manufacturing; laser powder-bed fusion; microstructure control; laser modulation; beam shaping

Citation Formats


                    Roehling, Tien T., Wu, Sheldon S. Q., Khairallah, Saad A., Roehling, John D., Soezeri, S. Stefan, Crumb, Michael F., and Matthews, Manyalibo J. Modulating laser intensity profile ellipticity for microstructural control during metal additive manufacturing.  United States: N. p., 2017. 
Web.  doi:10.1016/j.actamat.2017.02.025.

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                    Roehling, Tien T., Wu, Sheldon S. Q., Khairallah, Saad A., Roehling, John D., Soezeri, S. Stefan, Crumb, Michael F., & Matthews, Manyalibo J. Modulating laser intensity profile ellipticity for microstructural control during metal additive manufacturing.  United States.  https://doi.org/10.1016/j.actamat.2017.02.025

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                    Roehling, Tien T., Wu, Sheldon S. Q., Khairallah, Saad A., Roehling, John D., Soezeri, S. Stefan, Crumb, Michael F., and Matthews, Manyalibo J. Sat .  
"Modulating laser intensity profile ellipticity for microstructural control during metal additive manufacturing".  United States.  https://doi.org/10.1016/j.actamat.2017.02.025.

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@article{osti_1393688,

  title        = {Modulating laser intensity profile ellipticity for microstructural control during metal additive manufacturing},

  author       = {Roehling, Tien T. and Wu, Sheldon S. Q. and Khairallah, Saad A. and Roehling, John D. and Soezeri, S. Stefan and Crumb, Michael F. and Matthews, Manyalibo J.},

  abstractNote = {Additively manufactured (AM) metals are often highly textured, containing large columnar grains that initiate epitaxially under steep temperature gradients and rapid solidification conditions. These unique microstructures partially account for the massive property disparity existing between AM and conventionally processed alloys. Although equiaxed grains are desirable for isotropic mechanical behavior, the columnar-to-equiaxed transition remains difficult to predict for conventional solidification processes, and much more so for AM. In this study, the effects of laser intensity profile ellipticity on melt track macrostructures and microstructures were studied in 316L stainless steel. Experimental results were supported by temperature gradients and melt velocities simulated using the ALE3D multi-physics code. As a general trend, columnar grains preferentially formed with increasing laser power and scan speed for all beam profiles. However, when conduction mode laser heating occurs, scan parameters that result in coarse columnar microstructures using Gaussian profiles produce equiaxed or mixed equiaxed-columnar microstructures using elliptical profiles. Furthermore, by modulating spatial laser intensity profiles on the fly, site-specific microstructures and properties can be directly engineered into additively manufactured parts.},

  doi          = {10.1016/j.actamat.2017.02.025},

  journal      = {Acta Materialia},

  number       = C,

  volume       = 128,

  place        = {United States},

  year         = {Sat Apr 01 00:00:00 EDT 2017},

  month        = {Sat Apr 01 00:00:00 EDT 2017}

}

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Title: Modulating laser intensity profile ellipticity for microstructural control during metal additive manufacturing

Abstract

Citation Formats

Grain refinement induced by electromagnetic stirring: A dendrite fragmentation criterion journal, October 2004

In situ transmission electron microscopy of crystal growth-mode transitions during rapid solidification of a hypoeutectic Al–Cu alloy journal, February 2014

Columnar and equiaxed growth journal, March 1987

The coupled zone of rapidly solidified AlSi alloys in laser treatment journal, July 1992

Columnar to equiaxed transition in solidification processing journal, January 2001

Mapping and Modelling Single Scan Track Formation in Direct Metal Selective Laser Melting journal, January 2004

Simulation of the columnar-to-equiaxed transition in directionally solidified Al–Cu alloys journal, February 2005

Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing journal, December 2014

Theory of microstructural development during rapid solidification journal, May 1986

Textures formed in a CoCrMo alloy by selective laser melting journal, May 2015

The Effect of Rapid Solidification Velocity on the Microstructure of Ag-Cu Alloys journal, January 1984

Nucleation ahead of the advancing interface in directional solidification journal, June 1997

Denudation of metal powder layers in laser powder bed fusion processes journal, August 2016

Temperature distributions produced in semiconductors by a scanning elliptical or circular cw laser beam journal, January 1980

Theory of eutectic growth under rapid solidification conditions journal, April 1987

Mesoscopic simulation model of selective laser melting of stainless steel powder journal, November 2014

Phase-field simulation of the columnar-to-equiaxed transition in alloy solidification journal, May 2006

Aging Behaviour and Mechanical Performance of 18-Ni 300 Steel Processed by Selective Laser Melting journal, September 2016

Density of additively-manufactured, 316L SS parts using laser powder-bed fusion at powers up to 400 W journal, May 2014

About the banded structure in rapidly solidified dendritic and eutectic alloys journal, May 1992

Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder journal, March 2013

Dendrite growth in eutectic alloys: the coupled zone journal, January 1979

Hardened austenite steel with columnar sub-grain structure formed by laser melting journal, February 2015

Tailoring the grain structure of IN718 during selective electron beam melting journal, January 2014

Nonlinear calculation of a temperature profile produced in a two‐layer structure by a scanning cw elliptical laser or electron beam journal, February 1985

Development of microstructures in Fe−15Ni−15Cr single crystal electron beam welds journal, June 1989

In situ observations of dendritic fragmentation due to local solute-enrichment during directional solidification of an aluminum alloy journal, August 2007

The development of nucleation controlled microstructures during laser treatment of AlSi alloys journal, July 1996

Site specific control of crystallographic grain orientation through electron beam additive manufacturing journal, November 2014

Highly Anisotropic Steel Processed by Selective Laser Melting journal, May 2013

Physical Aspects of Process Control in Selective Laser Sintering of Metals journal, October 2003

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Single-crystal laser deposition of superalloys: processing–microstructure maps journal, April 2001

Simulation of the main physical processes in remote laser penetration with large laser spot size journal, April 2015

Dendrite fragmentation and the effects of fluid flow in castings journal, March 1997

Dendrite fragmentation by catastrophic elastic remelting journal, February 2009

X-ray Imaging and Controlled Solidification of Al-Cu Alloys Toward Microstructures by Design: X-ray Imaging and Controlled Solidification of Al-Cu Alloys journal, January 2015

An alternative method to determine critical pitting temperature of stainless steels in ferric chloride solution journal, January 1994

Strong morphological and crystallographic texture and resulting yield strength anisotropy in selective laser melted tantalum journal, July 2013

Characterization of the Microstructure Evolution and Microsegregation in a Ni-Based Superalloy under Super-High Thermal Gradient Directional Solidification journal, January 2012

Pitting corrosion behavior on crack property in AISI 304L weld metals with varying Cr/Ni equivalent ratio journal, September 2009

Marangoni Convection and Fragmentation in LASER Treatment journal, March 2006

Functionally Graded Alloys Obtained by Additive Manufacturing: Functionally Graded Alloys Obtained by Additive Manufacturing journal, March 2014

Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones journal, April 2016

Microsegregation-related pitting corrosion characteristics of AL-6XN superaustenitic stainless steel laser welds journal, October 2010

Dendrite growth at the limit of stability: tip radius and spacing journal, January 1981

Heat-flow simulation of laser remelting with experimenting validation journal, February 1991

Mechanical deformation of dendrites by fluid flow journal, January 1996

Steady state columnar and equiaxed growth of dendrites and eutectic journal, July 1984

Solidification microstructures and solid-state parallels: Recent developments, future directions journal, February 2009

Grain refinement induced by electromagnetic stirring: A dendrite fragmentation criterion
journal, October 2004

In situ transmission electron microscopy of crystal growth-mode transitions during rapid solidification of a hypoeutectic Al–Cu alloy
journal, February 2014

Columnar and equiaxed growth
journal, March 1987

The coupled zone of rapidly solidified AlSi alloys in laser treatment
journal, July 1992

Columnar to equiaxed transition in solidification processing
journal, January 2001

Mapping and Modelling Single Scan Track Formation in Direct Metal Selective Laser Melting
journal, January 2004

Simulation of the columnar-to-equiaxed transition in directionally solidified Al–Cu alloys
journal, February 2005

Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing
journal, December 2014

Theory of microstructural development during rapid solidification
journal, May 1986

Textures formed in a CoCrMo alloy by selective laser melting
journal, May 2015

The Effect of Rapid Solidification Velocity on the Microstructure of Ag-Cu Alloys
journal, January 1984

Nucleation ahead of the advancing interface in directional solidification
journal, June 1997

Denudation of metal powder layers in laser powder bed fusion processes
journal, August 2016

Temperature distributions produced in semiconductors by a scanning elliptical or circular cw laser beam
journal, January 1980

Theory of eutectic growth under rapid solidification conditions
journal, April 1987

Mesoscopic simulation model of selective laser melting of stainless steel powder
journal, November 2014

Phase-field simulation of the columnar-to-equiaxed transition in alloy solidification
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Aging Behaviour and Mechanical Performance of 18-Ni 300 Steel Processed by Selective Laser Melting
journal, September 2016

Density of additively-manufactured, 316L SS parts using laser powder-bed fusion at powers up to 400 W
journal, May 2014

About the banded structure in rapidly solidified dendritic and eutectic alloys
journal, May 1992

Fine-structured aluminium products with controllable texture by selective laser melting of pre-alloyed AlSi10Mg powder
journal, March 2013

Dendrite growth in eutectic alloys: the coupled zone
journal, January 1979

Hardened austenite steel with columnar sub-grain structure formed by laser melting
journal, February 2015

Tailoring the grain structure of IN718 during selective electron beam melting
journal, January 2014

Nonlinear calculation of a temperature profile produced in a two‐layer structure by a scanning cw elliptical laser or electron beam
journal, February 1985

Development of microstructures in Fe−15Ni−15Cr single crystal electron beam welds
journal, June 1989

In situ observations of dendritic fragmentation due to local solute-enrichment during directional solidification of an aluminum alloy
journal, August 2007

The development of nucleation controlled microstructures during laser treatment of AlSi alloys
journal, July 1996

Site specific control of crystallographic grain orientation through electron beam additive manufacturing
journal, November 2014

Highly Anisotropic Steel Processed by Selective Laser Melting
journal, May 2013

Physical Aspects of Process Control in Selective Laser Sintering of Metals
journal, October 2003

Austenitic stainless steel strengthened by the in situ formation of oxide nanoinclusions
journal, January 2015

Single-crystal laser deposition of superalloys: processing–microstructure maps
journal, April 2001

Simulation of the main physical processes in remote laser penetration with large laser spot size
journal, April 2015

Dendrite fragmentation and the effects of fluid flow in castings
journal, March 1997

Dendrite fragmentation by catastrophic elastic remelting
journal, February 2009

X-ray Imaging and Controlled Solidification of Al-Cu Alloys Toward Microstructures by Design: X-ray Imaging and Controlled Solidification of Al-Cu Alloys
journal, January 2015

An alternative method to determine critical pitting temperature of stainless steels in ferric chloride solution
journal, January 1994

Strong morphological and crystallographic texture and resulting yield strength anisotropy in selective laser melted tantalum
journal, July 2013

Characterization of the Microstructure Evolution and Microsegregation in a Ni-Based Superalloy under Super-High Thermal Gradient Directional Solidification
journal, January 2012

Pitting corrosion behavior on crack property in AISI 304L weld metals with varying Cr/Ni equivalent ratio
journal, September 2009

Marangoni Convection and Fragmentation in LASER Treatment
journal, March 2006

Functionally Graded Alloys Obtained by Additive Manufacturing: Functionally Graded Alloys Obtained by Additive Manufacturing
journal, March 2014

Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones
journal, April 2016

Microsegregation-related pitting corrosion characteristics of AL-6XN superaustenitic stainless steel laser welds
journal, October 2010

Dendrite growth at the limit of stability: tip radius and spacing
journal, January 1981

Heat-flow simulation of laser remelting with experimenting validation
journal, February 1991

Mechanical deformation of dendrites by fluid flow
journal, January 1996

Steady state columnar and equiaxed growth of dendrites and eutectic
journal, July 1984

Solidification microstructures and solid-state parallels: Recent developments, future directions
journal, February 2009