Pore elimination mechanisms during 3D printing of metals

Hojjatzadeh, S. Mohammad H.; Parab, Niranjan D.; Yan, Wentao; Guo, Qilin; Xiong, Lianghua; Zhao, Cang; Qu, Minglei; Escano, Luis I.; Xiao, Xianghui; Fezzaa, Kamel; Everhart, Wes; Sun, Tao; Chen, Lianyi

doi:10.1038/s41467-019-10973-9

Title: Pore elimination mechanisms during 3D printing of metals

Journal Article · 11 July 2019 · Nature Communications

DOI: https://doi.org/10.1038/s41467-019-10973-9 · OSTI ID:1572905

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Missouri Univ. of Science and Technology, Rolla, MO (United States)
Argonne National Lab. (ANL), Lemont, IL (United States)
National Univ. of Singapore (Singapore)
Honeywell FM&T, Kansas City, MO (United States)

Laser powder bed fusion (LPBF) is a 3D printing technology that can print metal parts with complex geometries without the design constraints of traditional manufacturing routes. However, the parts printed by LPBF normally contain many more pores than those made by conventional methods, which severely deteriorates their properties. Here, by combining in-situ high-speed high-resolution synchrotron x-ray imaging experiments and multi-physics modeling, we unveil the dynamics and mechanisms of pore motion and elimination in the LPBF process. We find that the high thermocapillary force, induced by the high temperature gradient in the laser interaction region, can rapidly eliminate pores from the melt pool during the LPBF process. The thermocapillary force driven pore elimination mechanism revealed here may guide the development of 3D printing approaches to achieve pore-free 3D printing of metals.

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

Sponsoring Organization:: USDOE Office of Enterprise Assessments, Kansas City National Security Campus; National Science Foundation (NSF); Argonne National Laboratory, Laboratory Directed Research and Development (LDRD); USDOE Office of Science (SC), Basic Energy Sciences (BES) (SC-22)

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 1572905

Journal Information:: Nature Communications, Journal Name: Nature Communications Journal Issue: 1 Vol. 10; ISSN 2041-1723

Publisher:: Nature Publishing GroupCopyright Statement

Country of Publication:: United States

Language:: English

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The origin of high-density dislocations in additively manufactured metals Wang, Ge; Ouyang, Heng; Fan, Chen Materials Research Letters, Vol. 8, Issue 8 https://doi.org/10.1080/21663831.2020.1751739	journal	April 2020
The origin of high-density dislocations in additively manufactured metals Wang, Ge; Ouyang, Heng; Fan, Chen Taylor & Francis https://doi.org/10.6084/m9.figshare.12204644	text	January 2020

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