In situ X-ray imaging of pore formation mechanisms and dynamics in laser powder-blown directed energy deposition additive manufacturing
Abstract
Directed energy deposition (DED) additive manufacturing (AM) is receiving growing attention in many applications, such as repair, remanufacturing, and fabrication of functionally graded structures. However, the laser-matter interactions and melt pool dynamics in laser DED with powder flow are still unclear, particularly in how pores form and flow inside the melt pool during the process. Understanding the porosity formation mechanisms is critical in the qualification, certification, and overall properties of a DED AM part. Porosity is a common phenomenon and can significantly hinder the quality of DED fabricated parts, as the pores can act as sites of crack nucleation and propagation. Here in this paper, we reveal four types of pore formation mechanisms through in-situ and operando high-speed high-resolution X-ray imaging in the DED AM process. Our results confirm that porosity within the feedstock powder induces pores in the process. We also observed pore formation mechanisms unique to the laser-based, powder-blown DED process as a result of powder delivery, keyhole dynamics, melt pool dynamics, and shield gas. High-speed X-ray images provide direct evidence for pore formation mechanisms and show that the pores related to the interaction between the delivered powder and melt pool are the largest in size in laser-basedmore »
- Authors:
-
[1];
[3];
- Texas A & M Univ., College Station, TX (United States)
- Argonne National Lab. (ANL), Argonne, IL (United States)
- Carnegie Mellon Univ., Pittsburgh, PA (United States)
- Publication Date:
- Research Org.:
- Argonne National Lab. (ANL), Argonne, IL (United States)
- Sponsoring Org.:
- USDOE Laboratory Directed Research and Development (LDRD) Program; USDOE Office of Science (SC)
- OSTI Identifier:
- 1819709
- Alternate Identifier(s):
- OSTI ID: 1815255
- Grant/Contract Number:
- AC02-06CH11357
- Resource Type:
- Accepted Manuscript
- Journal Name:
- International Journal of Machine Tools and Manufacture
- Additional Journal Information:
- Journal Volume: 166; Journal ID: ISSN 0890-6955
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; Additive manufacturing; Directed energy deposition; Laser; Pore formation; Porosity; X-ray imaging
Citation Formats
Wolff, Sarah J., Wang, Hui, Gould, Benjamin, Parab, Niranjan, Wu, Ziheng, Zhao, Cang, Greco, Aaron, and Sun, Tao. In situ X-ray imaging of pore formation mechanisms and dynamics in laser powder-blown directed energy deposition additive manufacturing. United States: N. p., 2021.
Web. doi:10.1016/j.ijmachtools.2021.103743.
Wolff, Sarah J., Wang, Hui, Gould, Benjamin, Parab, Niranjan, Wu, Ziheng, Zhao, Cang, Greco, Aaron, & Sun, Tao. In situ X-ray imaging of pore formation mechanisms and dynamics in laser powder-blown directed energy deposition additive manufacturing. United States. https://doi.org/10.1016/j.ijmachtools.2021.103743
Wolff, Sarah J., Wang, Hui, Gould, Benjamin, Parab, Niranjan, Wu, Ziheng, Zhao, Cang, Greco, Aaron, and Sun, Tao. Thu .
"In situ X-ray imaging of pore formation mechanisms and dynamics in laser powder-blown directed energy deposition additive manufacturing". United States. https://doi.org/10.1016/j.ijmachtools.2021.103743. https://www.osti.gov/servlets/purl/1819709.
@article{osti_1819709,
title = {In situ X-ray imaging of pore formation mechanisms and dynamics in laser powder-blown directed energy deposition additive manufacturing},
author = {Wolff, Sarah J. and Wang, Hui and Gould, Benjamin and Parab, Niranjan and Wu, Ziheng and Zhao, Cang and Greco, Aaron and Sun, Tao},
abstractNote = {Directed energy deposition (DED) additive manufacturing (AM) is receiving growing attention in many applications, such as repair, remanufacturing, and fabrication of functionally graded structures. However, the laser-matter interactions and melt pool dynamics in laser DED with powder flow are still unclear, particularly in how pores form and flow inside the melt pool during the process. Understanding the porosity formation mechanisms is critical in the qualification, certification, and overall properties of a DED AM part. Porosity is a common phenomenon and can significantly hinder the quality of DED fabricated parts, as the pores can act as sites of crack nucleation and propagation. Here in this paper, we reveal four types of pore formation mechanisms through in-situ and operando high-speed high-resolution X-ray imaging in the DED AM process. Our results confirm that porosity within the feedstock powder induces pores in the process. We also observed pore formation mechanisms unique to the laser-based, powder-blown DED process as a result of powder delivery, keyhole dynamics, melt pool dynamics, and shield gas. High-speed X-ray images provide direct evidence for pore formation mechanisms and show that the pores related to the interaction between the delivered powder and melt pool are the largest in size in laser-based powder-blown DED AM. These results will guide porosity mitigation, elimination, and control in DED AM.},
doi = {10.1016/j.ijmachtools.2021.103743},
journal = {International Journal of Machine Tools and Manufacture},
number = ,
volume = 166,
place = {United States},
year = {Thu May 06 00:00:00 EDT 2021},
month = {Thu May 06 00:00:00 EDT 2021}
}
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