Effect of laser power on roughness and porosity in laser powder bed fusion of stainless steel 316L alloys measured by X-ray tomography

Forien, Jean-Baptiste; Depond, Philip J.; Guss, Gabe M.; Jared, Bradley H.; Madison, Jonathan D.; Matthews, Manyalibo J.

doi:10.3139/146.111816

Title: Effect of laser power on roughness and porosity in laser powder bed fusion of stainless steel 316L alloys measured by X-ray tomography

Journal Article · 31 December 2019 · International Journal of Materials Research

DOI: https://doi.org/10.3139/146.111816 · OSTI ID:1573157

Forien, Jean-Baptiste ^[1]; Depond, Philip J. ^[1]; Guss, Gabe M. ^[1]; Jared, Bradley H. ^[2]; Madison, Jonathan D. ^[2]; Matthews, Manyalibo J. ^[1]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

The quality of metal objects fabricated via laser powder bed fusion are highly affected by process parameters, and their influence on final products is yet to be fully explored. In this work, pyrometry signals of the melt pool were collected from a set of stainless-steel samples during manufacturing and the effect of laser power on porosity and roughness of final printed parts was analyzed. Results show that the melt pool pyrometry signal of contours increases with higher laser power, whereas it is lower and decreases for the infilled part. Post-built X-ray computed tomography imaging reveals that porosity decreases while sample roughness increases upon increasing laser power. The decrease in porosity with increasing laser power is attributed to the larger size of the contour welds that were printed first, leading to an increase in dimension of the final products.

View Accepted Manuscript (DOE)

Cite

Export

Save

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

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: AC52-07NA27344

OSTI ID:: 1573157

Report Number(s):: LLNL-JRNL--780397; 948172

Journal Information:: International Journal of Materials Research, Journal Name: International Journal of Materials Research Journal Issue: 1 Vol. 111; ISSN 1862-5282

Publisher:: Carl Hanser VerlagCopyright Statement

Country of Publication:: United States

Language:: English

References (44)

High-Resolution Microfocus X-Ray Computed Tomography for 3D Surface Roughness Measurements of Additive Manufactured Porous Materials Kerckhofs, Greet; Pyka, Grzegorz; Moesen, Maarten Advanced Engineering Materials, Vol. 15, Issue 3 https://doi.org/10.1002/adem.201200156	journal	October 2012
Machine‐Learning‐Based Monitoring of Laser Powder Bed Fusion Yuan, Bodi; Guss, Gabriel M.; Wilson, Aaron C. Advanced Materials Technologies, Vol. 3, Issue 12 https://doi.org/10.1002/admt.201800136	journal	August 2018
Additive manufacturing and its societal impact: a literature review Huang, Samuel H.; Liu, Peng; Mokasdar, Abhiram The International Journal of Advanced Manufacturing Technology, Vol. 67, Issue 5-8 https://doi.org/10.1007/s00170-012-4558-5	journal	October 2012
Prediction of microstructure, residual stress, and deformation in laser powder bed fusion process Yang, Y. P.; Jamshidinia, M.; Boulware, P. Computational Mechanics, Vol. 61, Issue 5 https://doi.org/10.1007/s00466-017-1528-7	journal	December 2017
Defect Formation Mechanisms in Selective Laser Melting: A Review Zhang, Bi; Li, Yongtao; Bai, Qian Chinese Journal of Mechanical Engineering, Vol. 30, Issue 3 https://doi.org/10.1007/s10033-017-0121-5	journal	April 2017
A Study on the Laser Spatter and the Oxidation Reactions During Selective Laser Melting of 316L Stainless Steel, Al-Si10-Mg, and Ti-6Al-4V Simonelli, Marco; Tuck, Chris; Aboulkhair, Nesma T. Metallurgical and Materials Transactions A, Vol. 46, Issue 9 https://doi.org/10.1007/s11661-015-2882-8	journal	April 2015
Influence of Powder Characteristics on Formation of Porosity in Additive Manufacturing of Ti-6Al-4V Components Iebba, Maurizio; Astarita, Antonello; Mistretta, Daniela Journal of Materials Engineering and Performance, Vol. 26, Issue 8 https://doi.org/10.1007/s11665-017-2796-2	journal	June 2017
Synchrotron-Based X-ray Microtomography Characterization of the Effect of Processing Variables on Porosity Formation in Laser Power-Bed Additive Manufacturing of Ti-6Al-4V Cunningham, Ross; Narra, Sneha P.; Montgomery, Colt JOM, Vol. 69, Issue 3 https://doi.org/10.1007/s11837-016-2234-1	journal	January 2017
Process monitoring and inspection systems in metal additive manufacturing: Status and applications Chua, Zhong Yang; Ahn, Il Hyuk; Moon, Seung Ki International Journal of Precision Engineering and Manufacturing-Green Technology, Vol. 4, Issue 2 https://doi.org/10.1007/s40684-017-0029-7	journal	April 2017
Metal Fabrication by Additive Manufacturing Using Laser and Electron Beam Melting Technologies Murr, Lawrence E.; Gaytan, Sara M.; Ramirez, Diana A. Journal of Materials Science & Technology, Vol. 28, Issue 1 https://doi.org/10.1016/S1005-0302(12)60016-4	journal	January 2012
Application of X-ray CT method for discontinuity and porosity detection in 316L stainless steel parts produced with SLM technology Ziółkowski, G.; Chlebus, E.; Szymczyk, P. Archives of Civil and Mechanical Engineering, Vol. 14, Issue 4 https://doi.org/10.1016/j.acme.2014.02.003	journal	August 2014
3D-imaging of selective laser melting defects in a Co–Cr–Mo alloy by synchrotron radiation micro-CT Zhou, Xin; Wang, Dianzheng; Liu, Xihe Acta Materialia, Vol. 98 https://doi.org/10.1016/j.actamat.2015.07.014	journal	October 2015
3D multi-layer grain structure simulation of powder bed fusion additive manufacturing Koepf, Johannes A.; Gotterbarm, Martin R.; Markl, Matthias Acta Materialia, Vol. 152 https://doi.org/10.1016/j.actamat.2018.04.030	journal	June 2018
Reducing porosity in AlSi10Mg parts processed by selective laser melting Aboulkhair, Nesma T.; Everitt, Nicola M.; Ashcroft, Ian Additive Manufacturing, Vol. 1-4 https://doi.org/10.1016/j.addma.2014.08.001	journal	October 2014
Understanding the effect of laser scan strategy on residual stress in selective laser melting through thermo-mechanical simulation Parry, L.; Ashcroft, I. A.; Wildman, R. D. Additive Manufacturing, Vol. 12 https://doi.org/10.1016/j.addma.2016.05.014	journal	October 2016
Determination of the effect of scan strategy on residual stress in laser powder bed fusion additive manufacturing Robinson, J.; Ashton, I.; Fox, P. Additive Manufacturing, Vol. 23 https://doi.org/10.1016/j.addma.2018.07.001	journal	October 2018
Laser-matter interactions in additive manufacturing of stainless steel SS316L and 13-93 bioactive glass revealed by in situ X-ray imaging Leung, Chu Lun Alex; Marussi, Sebastian; Towrie, Michael Additive Manufacturing, Vol. 24 https://doi.org/10.1016/j.addma.2018.08.025	journal	December 2018
BoneJ: Free and extensible bone image analysis in ImageJ Doube, Michael; Kłosowski, Michał M.; Arganda-Carreras, Ignacio Bone, Vol. 47, Issue 6 https://doi.org/10.1016/j.bone.2010.08.023	journal	December 2010
High resolution pore size analysis in metallic powders by X-ray tomography Heim, K.; Bernier, F.; Pelletier, R. Case Studies in Nondestructive Testing and Evaluation, Vol. 6 https://doi.org/10.1016/j.csndt.2016.09.002	journal	November 2016
Selective laser melting of Ti6Al4V alloy for biomedical applications: Temperature monitoring and microstructural evolution Yadroitsev, I.; Krakhmalev, P.; Yadroitsava, I. Journal of Alloys and Compounds, Vol. 583 https://doi.org/10.1016/j.jallcom.2013.08.183	journal	January 2014
Additive manufactured porous titanium structures: Through-process quantification of pore and strut networks Kim, Taek Bo; Yue, Sheng; Zhang, Ziyu Journal of Materials Processing Technology, Vol. 214, Issue 11 https://doi.org/10.1016/j.jmatprotec.2014.05.006	journal	November 2014
XCT analysis of the influence of melt strategies on defect population in Ti–6Al–4V components manufactured by Selective Electron Beam Melting Tammas-Williams, S.; Zhao, H.; Léonard, F. Materials Characterization, Vol. 102 https://doi.org/10.1016/j.matchar.2015.02.008	journal	April 2015
Correlation between porosity and processing parameters in TiAl6V4 produced by selective laser melting Kasperovich, Galina; Haubrich, Jan; Gussone, Joachim Materials & Design, Vol. 105 https://doi.org/10.1016/j.matdes.2016.05.070	journal	September 2016
The influence of laser parameters and scanning strategies on the mechanical properties of a stochastic porous material Ghouse, Shaaz; Babu, Sarat; Van Arkel, Richard J. Materials & Design, Vol. 131 https://doi.org/10.1016/j.matdes.2017.06.041	journal	October 2017
In situ measurements of layer roughness during laser powder bed fusion additive manufacturing using low coherence scanning interferometry DePond, Philip J.; Guss, Gabe; Ly, Sonny Materials & Design, Vol. 154 https://doi.org/10.1016/j.matdes.2018.05.050	journal	September 2018
Damage evolution and failure mechanisms in additively manufactured stainless steel Carlton, Holly D.; Haboub, Abdel; Gallegos, Gilbert F. Materials Science and Engineering: A, Vol. 651 https://doi.org/10.1016/j.msea.2015.10.073	journal	January 2016
Effect of scanning strategies on residual stress and mechanical properties of Selective Laser Melted Ti6Al4V Ali, Haider; Ghadbeigi, Hassan; Mumtaz, Kamran Materials Science and Engineering: A, Vol. 712 https://doi.org/10.1016/j.msea.2017.11.103	journal	January 2018
Determination of geometrical factors in Layerwise Laser Melting using optical process monitoring Craeghs, Tom; Clijsters, Stijn; Yasa, Evren Optics and Lasers in Engineering, Vol. 49, Issue 12 https://doi.org/10.1016/j.optlaseng.2011.06.016	journal	December 2011
Feedback control of Layerwise Laser Melting using optical sensors Craeghs, Tom; Bechmann, Florian; Berumen, Sebastian Physics Procedia, Vol. 5 https://doi.org/10.1016/j.phpro.2010.08.078	journal	January 2010
On-line temperature monitoring in selective laser sintering/melting Chivel, Yu.; Smurov, I. Physics Procedia, Vol. 5 https://doi.org/10.1016/j.phpro.2010.08.079	journal	January 2010
Pyrometric analysis of thermal processes in SLM technology Pavlov, M.; Doubenskaia, M.; Smurov, I. Physics Procedia, Vol. 5 https://doi.org/10.1016/j.phpro.2010.08.080	journal	January 2010
Reduction of the Residual Porosity in Parts Manufactured by Selective Laser Melting Using Skywriting and High Focus Offset Strategies Mancisidor, A. M.; Garciandia, F.; Sebastian, M. San Physics Procedia, Vol. 83 https://doi.org/10.1016/j.phpro.2016.08.090	journal	January 2016
Pyrometry in laser surface treatment Doubenskaia, M.; Bertrand, Ph.; Smurov, I. Surface and Coatings Technology, Vol. 201, Issue 5 https://doi.org/10.1016/j.surfcoat.2006.04.060	journal	October 2006
Fiji: an open-source platform for biological-image analysis Schindelin, Johannes; Arganda-Carreras, Ignacio; Frise, Erwin Nature Methods, Vol. 9, Issue 7 https://doi.org/10.1038/nmeth.2019	journal	June 2012
In situ X-ray imaging of defect and molten pool dynamics in laser additive manufacturing Leung, Chu Lun Alex; Marussi, Sebastian; Atwood, Robert C. Nature Communications, Vol. 9, Issue 1 https://doi.org/10.1038/s41467-018-03734-7	journal	April 2018
Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing Ly, Sonny; Rubenchik, Alexander M.; Khairallah, Saad A. Scientific Reports, Vol. 7, Issue 1 https://doi.org/10.1038/s41598-017-04237-z	journal	June 2017
An instrument for in situ time-resolved X-ray imaging and diffraction of laser powder bed fusion additive manufacturing processes Calta, Nicholas P.; Wang, Jenny; Kiss, Andrew M. Review of Scientific Instruments, Vol. 89, Issue 5 https://doi.org/10.1063/1.5017236	journal	May 2018
Theoretical analysis of photodiode monitoring of laser welding defects by imaging combined with modelling Norman, P.; Engström, H.; Kaplan, A. F. H. Journal of Physics D: Applied Physics, Vol. 41, Issue 19 https://doi.org/10.1088/0022-3727/41/19/195502	journal	September 2008
Real-time optical pyrometer in laser machining Ignatiev, M.; Smurov, I.; Flamant, G. Measurement Science and Technology, Vol. 5, Issue 5 https://doi.org/10.1088/0957–0233/5/5/016	journal	May 1994
Process defects and in situ monitoring methods in metal powder bed fusion: a review Grasso, Marco; Colosimo, Bianca Maria Measurement Science and Technology, Vol. 28, Issue 4 https://doi.org/10.1088/1361-6501/aa5c4f	journal	February 2017
Directionality of Cavities and Porosity Formation in Powder-Bed Laser Additive Manufacturing of Metal Components Investigated Using X-Ray Tomography du Plessis, Anton; le Roux, Stephan Gerhard; Booysen, Gerrie 3D Printing and Additive Manufacturing, Vol. 3, Issue 1 https://doi.org/10.1089/3dp.2015.0034	journal	March 2016
MorphoLibJ: integrated library and plugins for mathematical morphology with ImageJ Legland, David; Arganda-Carreras, Ignacio; Andrey, Philippe Bioinformatics https://doi.org/10.1093/bioinformatics/btw413	journal	July 2016
Selective laser melting process monitoring with high speed infra-red camera and pyrometer Bayle, F.; Doubenskaia, M. SPIE Proceedings https://doi.org/10.1117/12.786940	conference	February 2012
Optical System for On-Line Monitoring and Temperature Control in Selective Laser Melting Technology Doubenskaia, Maria; Pavlov, Mikhail; Chivel, Yuri Key Engineering Materials, Vol. 437 https://doi.org/10.4028/www.scientific.net/KEM.437.458	journal	May 2010

Similar Records

Melt Pool characteristics on surface roughness and printability of 316L stainless steel in laser powder bed fusion

Journal Article · 2024 · Rapid Prototyping Journal · OSTI ID:2582669

Zhang, Tianyu; Yuan, Lang

Effect of laser power on defect, texture, and microstructure of a laser powder bed fusion processed 316L stainless steel

Journal Article · 2019 · Materials & Design · OSTI ID:1477038

Choo, Hahn; Sham, Kin-Ling; Bohling, John; +6 more

Detecting keyhole porosity and monitoring process signatures in additive manufacturing: an in situ pyrometry and ex situ X-ray radiography correlation

Journal Article · 2020 · Additive Manufacturing · OSTI ID:1635089

Forien, J; Calta, N; DePond, P; +3 more

Related Subjects

36 MATERIALS SCIENCE
Laser powder bed fusion
Porosity
Pyrometry
Roughness
X-ray tomography

Title: Effect of laser power on roughness and porosity in laser powder bed fusion of stainless steel 316L alloys measured by X-ray tomography

Citation Formats

References (44)

Similar Records

Related Subjects