A laser powder bed fusion system for operando synchrotron x-ray imaging and correlative diagnostic experiments at the Stanford Synchrotron Radiation Lightsource

Martin, Aiden A.; Wang, Jenny; DePond, Philip J.; Strantza, Maria; Forien, Jean-Baptiste; Gorgannejad, Sanam; Guss, Gabriel M.; Thampy, Vivek; Fong, Anthony Y.; Weker, Johanna Nelson; Stone, Kevin H.; Tassone, Christopher J.; Matthews, Manyalibo J.; Calta, Nicholas P.

doi:10.1063/5.0080724

Title: A laser powder bed fusion system for operando synchrotron x-ray imaging and correlative diagnostic experiments at the Stanford Synchrotron Radiation Lightsource

Journal Article · 31 March 2022 · Review of Scientific Instruments

DOI: https://doi.org/10.1063/5.0080724 · OSTI ID:1880936

^[1]; Wang, Jenny ^[1]; DePond, Philip J. ^[1]; Strantza, Maria ^[1];

^[1]; Gorgannejad, Sanam ^[1]; Guss, Gabriel M. ^[1]; Thampy, Vivek ^[2];

^[2];

^[2]; Tassone, Christopher J. ^[2]; Matthews, Manyalibo J. ^[1]; Calta, Nicholas P. ^[1]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
SLAC National Accelerator Lab., Menlo Park, CA (United States)

Laser powder bed fusion (LPBF) is a highly dynamic multi-physics process used for the additive manufacturing (AM) of metal components. Improving process understanding and validating predictive computational models require high-fidelity diagnostics capable of capturing data in challenging environments. Synchrotron x-ray techniques play a vital role in the validation process as they are the only in situ diagnostic capable of imaging sub-surface melt pool dynamics and microstructure evolution during LPBF-AM. In this article, a laboratory scale system designed to mimic LPBF process conditions while operating at a synchrotron facility is described. The system is implemented with process accurate atmospheric conditions, including an air knife for active vapor plume removal. Significantly, the chamber also incorporates a diagnostic sensor suite that monitors emitted optical, acoustic, and electronic signals during laser processing with coincident x-ray imaging. The addition of the sensor suite enables validation of these industrially compatible single point sensors by detecting pore formation and spatter events and directly correlating the events with changes in the detected signal. Experiments in the Ti–6Al–4V alloy performed at the Stanford Synchrotron Radiation Lightsource using the system are detailed with sufficient sampling rates to probe melt pool dynamics. X-ray imaging captures melt pool dynamics at frame rates of 20 kHz with a 2 µm pixel resolution, and the coincident diagnostic sensor data are recorded at 470 kHz. Furthermore, this work shows that the current system enables the in situ detection of defects during the LPBF process and permits direct correlation of diagnostic signatures at the exact time of defect formation.

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; AC02-76SF00515

OSTI ID:: 1880936

Alternate ID(s):: OSTI ID: 1860528; OSTI ID: 1882689

Report Number(s):: LLNL-JRNL-829176; 1044923

Journal Information:: Review of Scientific Instruments, Journal Name: Review of Scientific Instruments Journal Issue: 4 Vol. 93; ISSN 0034-6748

Publisher:: American Institute of Physics (AIP)Copyright Statement

Country of Publication:: United States

Language:: English

References (50)

The causal relationship between melt pool geometry and energy absorption measured in real time during laser-based manufacturing Simonds, Brian J.; Tanner, Jack; Artusio-Glimpse, Alexandra Applied Materials Today, Vol. 23 https://doi.org/10.1016/j.apmt.2021.101049	journal	June 2021
Ultrafast X-ray imaging of laser–metal additive manufacturing processes Parab, Niranjan D.; Zhao, Cang; Cunningham, Ross Journal of Synchrotron Radiation, Vol. 25, Issue 5 https://doi.org/10.1107/s1600577518009554	journal	August 2018
Experimental observation of stress formation during selective laser melting using in situ X-ray diffraction Schmeiser, Felix; Krohmer, Erwin; Schell, Norbert Additive Manufacturing, Vol. 32 https://doi.org/10.1016/j.addma.2019.101028	journal	March 2020
In situ / operando synchrotron x-ray studies of metal additive manufacturing Sun, Tao; Tan, Wenda; Chen, Lianyi MRS Bulletin, Vol. 45, Issue 11 https://doi.org/10.1557/mrs.2020.275	journal	November 2020
Visualization of the shielding gas flow in SLM machines by space-resolved thermal anemometry Schniedenharn, Maximilian; Wiedemann, Frederik; Schleifenbaum, Johannes Henrich Rapid Prototyping Journal, Vol. 24, Issue 8 https://doi.org/10.1108/rpj-07-2017-0149	journal	October 2018
Detecting keyhole pore defects and monitoring process signatures during laser powder bed fusion: A correlation between in situ pyrometry and ex situ X-ray radiography Forien, Jean-Baptiste; Calta, Nicholas P.; DePond, Philip J. Additive Manufacturing, Vol. 35 https://doi.org/10.1016/j.addma.2020.101336	journal	October 2020
Numerical and experimental investigation into gas flow field and spattering phenomena in laser powder bed fusion processing of Inconel 718 Chien, Cheng-Yen; Le, Trong-Nhan; Lin, Ze-Hong Materials & Design, Vol. 210 https://doi.org/10.1016/j.matdes.2021.110107	journal	November 2021
A Finite Energy Bandwidth-Based Diffraction Simulation Framework for Thermal Processing Applications Pagan, Darren C.; Jones, Kevontrez K.; Bernier, Joel V. JOM, Vol. 72, Issue 12 https://doi.org/10.1007/s11837-020-04443-7	journal	October 2020
Transient dynamics of powder spattering in laser powder bed fusion additive manufacturing process revealed by in-situ high-speed high-energy x-ray imaging Guo, Qilin; Zhao, Cang; Escano, Luis I. Acta Materialia, Vol. 151 https://doi.org/10.1016/j.actamat.2018.03.036	journal	June 2018
Critical instability at moving keyhole tip generates porosity in laser melting Zhao, Cang; Parab, Niranjan D.; Li, Xuxiao Science, Vol. 370, Issue 6520 https://doi.org/10.1126/science.abd1587	journal	November 2020
Correlations between thermal history and keyhole porosity in laser powder bed fusion Paulson, Noah H.; Gould, Benjamin; Wolff, Sarah J. Additive Manufacturing, Vol. 34 https://doi.org/10.1016/j.addma.2020.101213	journal	August 2020
Melt pool temperature and cooling rates in laser powder bed fusion Hooper, Paul A. Additive Manufacturing, Vol. 22 https://doi.org/10.1016/j.addma.2018.05.032	journal	August 2018
Dynamics of pore formation during laser powder bed fusion additive manufacturing Martin, Aiden A.; Calta, Nicholas P.; Khairallah, Saad A. Nature Communications, Vol. 10, Issue 1 https://doi.org/10.1038/s41467-019-10009-2	journal	April 2019
In-situ full-field mapping of melt flow dynamics in laser metal additive manufacturing Guo, Qilin; Zhao, Cang; Qu, Minglei Additive Manufacturing, Vol. 31 https://doi.org/10.1016/j.addma.2019.100939	journal	January 2020
In situ radiographic and ex situ tomographic analysis of pore interactions during multilayer builds in laser powder bed fusion Sinclair, Lorna; Leung, Chu Lun Alex; Marussi, Sebastian Additive Manufacturing, Vol. 36 https://doi.org/10.1016/j.addma.2020.101512	journal	December 2020
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
Operando X-ray diffraction during laser 3D printing Hocine, Samy; Van Swygenhoven, Helena; Van Petegem, Steven Materials Today, Vol. 34 https://doi.org/10.1016/j.mattod.2019.10.001	journal	April 2020
High speed synchrotron X-ray diffraction experiments resolve microstructure and phase transformation in laser processed Ti-6Al-4V Oh, Seunghee A.; Lim, Rachel E.; Aroh, Joseph W. Materials Research Letters, Vol. 9, Issue 10 https://doi.org/10.1080/21663831.2021.1966537	journal	August 2021
Microscale Observation via High-Speed X-ray Diffraction of Alloy 718 During In Situ Laser Melting Oh, Seunghee A.; Lim, Rachel E.; Aroh, Joseph W. JOM, Vol. 73, Issue 1 https://doi.org/10.1007/s11837-020-04481-1	journal	November 2020
Effect of Laser-Matter Interaction on Molten Pool Flow and Keyhole Dynamics Kouraytem, Nadia; Li, Xuxiao; Cunningham, Ross Physical Review Applied, Vol. 11, Issue 6 https://doi.org/10.1103/physrevapplied.11.064054	journal	June 2019
Controlling interdependent meso-nanosecond dynamics and defect generation in metal 3D printing Khairallah, Saad A.; Martin, Aiden A.; Lee, Jonathan R. I. Science, Vol. 368, Issue 6491 https://doi.org/10.1126/science.aay7830	journal	May 2020
In-situ Synchrotron imaging of keyhole mode multi-layer laser powder bed fusion additive manufacturing Chen, Yunhui; Clark, Samuel J.; Leung, Chu Lun Alex Applied Materials Today, Vol. 20 https://doi.org/10.1016/j.apmt.2020.100650	journal	September 2020
In Situ Analysis of Laser Powder Bed Fusion Using Simultaneous High-Speed Infrared and X-ray Imaging Gould, Benjamin; Wolff, Sarah; Parab, Niranjan JOM, Vol. 73, Issue 1 https://doi.org/10.1007/s11837-020-04291-5	journal	July 2020
Capturing Marangoni flow via synchrotron imaging of selective laser melting Clark, S. J.; Leung, C. L. A.; Chen, Y. IOP Conference Series: Materials Science and Engineering, Vol. 861, Issue 1 https://doi.org/10.1088/1757-899x/861/1/012010	journal	May 2020
Laser‐Induced Keyhole Defect Dynamics during Metal Additive Manufacturing Kiss, Andrew M.; Fong, Anthony Y.; Calta, Nicholas P. Advanced Engineering Materials, Vol. 21, Issue 10 https://doi.org/10.1002/adem.201900455	journal	August 2019
Analysis of laser-induced microcracking in tungsten under additive manufacturing conditions: Experiment and simulation Vrancken, Bey; Ganeriwala, Rishi K.; Matthews, Manyalibo J. Acta Materialia, Vol. 194 https://doi.org/10.1016/j.actamat.2020.04.060	journal	August 2020
A laser powder bed fusion system for in situ x-ray diffraction with high-energy synchrotron radiation Uhlmann, Eckart; Krohmer, Erwin; Schmeiser, Felix Review of Scientific Instruments, Vol. 91, Issue 7 https://doi.org/10.1063/1.5143766	journal	July 2020
Subsurface Cooling Rates and Microstructural Response during Laser Based Metal Additive Manufacturing Thampy, Vivek; Fong, Anthony Y.; Calta, Nicholas P. Scientific Reports, Vol. 10, Issue 1 https://doi.org/10.1038/s41598-020-58598-z	journal	February 2020
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
Solidification crack propagation and morphology dependence on processing parameters in AA6061 from ultra-high-speed x-ray visualization Kouraytem, Nadia; Chiang, Po-Ju; Jiang, Runbo Additive Manufacturing, Vol. 42 https://doi.org/10.1016/j.addma.2021.101959	journal	June 2021
Denudation of metal powder layers in laser powder bed fusion processes Matthews, Manyalibo J.; Guss, Gabe; Khairallah, Saad A. Acta Materialia, Vol. 114 https://doi.org/10.1016/j.actamat.2016.05.017	journal	August 2016
Keyhole threshold and morphology in laser melting revealed by ultrahigh-speed x-ray imaging Cunningham, Ross; Zhao, Cang; Parab, Niranjan Science, Vol. 363, Issue 6429 https://doi.org/10.1126/science.aav4687	journal	February 2019
In situ investigation of phase transformations in Ti-6Al-4V under additive manufacturing conditions combining laser melting and high-speed micro-X-ray diffraction Kenel, C.; Grolimund, D.; Li, X. Scientific Reports, Vol. 7, Issue 1 https://doi.org/10.1038/s41598-017-16760-0	journal	November 2017
Enhanced mechanical performance via laser induced nanostructure formation in an additively manufactured lightweight aluminum alloy Martin, Aiden A.; Hammons, Joshua A.; Henderson, Hunter B. Applied Materials Today, Vol. 22 https://doi.org/10.1016/j.apmt.2021.100972	journal	March 2021
Ultrafast dynamics of laser-metal interactions in additive manufacturing alloys captured by in situ X-ray imaging Martin, Aiden A.; Calta, Nicholas P.; Hammons, Joshua A. Materials Today Advances, Vol. 1 https://doi.org/10.1016/j.mtadv.2019.01.001	journal	March 2019
Pressure dependence of the laser-metal interaction under laser powder bed fusion conditions probed by in situ X-ray imaging Calta, Nicholas P.; Martin, Aiden A.; Hammons, Joshua A. Additive Manufacturing, Vol. 32 https://doi.org/10.1016/j.addma.2020.101084	journal	March 2020
A miniaturized selective laser melting device for operando X-ray diffraction studies Hocine, Samy; Van Petegem, Steven; Frommherz, Ulrich Additive Manufacturing, Vol. 34 https://doi.org/10.1016/j.addma.2020.101194	journal	August 2020
Pore elimination mechanisms during 3D printing of metals Hojjatzadeh, S. Mohammad H.; Parab, Niranjan D.; Yan, Wentao Nature Communications, Vol. 10, Issue 1 https://doi.org/10.1038/s41467-019-10973-9	journal	July 2019
Fluid and particle dynamics in laser powder bed fusion Bidare, P.; Bitharas, I.; Ward, R. M. Acta Materialia, Vol. 142 https://doi.org/10.1016/j.actamat.2017.09.051	journal	January 2018
Achieving homogeneity in a high-Fe β-Ti alloy laser-printed from blended elemental powders Ahmed, Farheen F.; Clark, Samuel J.; Alex Leung, Chu Lun Materials & Design, Vol. 210 https://doi.org/10.1016/j.matdes.2021.110072	journal	November 2021
A method for objectively evaluating the defect detection performance of in-situ monitoring systems de Winton, Henry C.; Cegla, Frederic; Hooper, Paul A. Additive Manufacturing, Vol. 48 https://doi.org/10.1016/j.addma.2021.102431	journal	December 2021
Supervised deep learning for real-time quality monitoring of laser welding with X-ray radiographic guidance Shevchik, Sergey; Le-Quang, Tri; Meylan, Bastian Scientific Reports, Vol. 10, Issue 1 https://doi.org/10.1038/s41598-020-60294-x	journal	February 2020
Laser-metal interaction dynamics during additive manufacturing resolved by detection of thermally-induced electron emission DePond, Philip J.; Fuller, John C.; Khairallah, Saad A. Communications Materials, Vol. 1, Issue 1 https://doi.org/10.1038/s43246-020-00094-y	journal	November 2020
The effect of powder oxidation on defect formation in laser additive manufacturing Leung, Chu Lun Alex; Marussi, Sebastian; Towrie, Michael Acta Materialia, Vol. 166 https://doi.org/10.1016/j.actamat.2018.12.027	journal	March 2019
On the effect of shielding gas flow on porosity and melt pool geometry in laser powder bed fusion additive manufacturing Reijonen, Joni; Revuelta, Alejandro; Riipinen, Tuomas Additive Manufacturing, Vol. 32 https://doi.org/10.1016/j.addma.2019.101030	journal	March 2020
Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction Zhao, Cang; Fezzaa, Kamel; Cunningham, Ross W. Scientific Reports, Vol. 7, Issue 1 https://doi.org/10.1038/s41598-017-03761-2	journal	June 2017
In situ characterization of laser-generated melt pools using synchronized ultrasound and high-speed X-ray imaging Gillespie, Jared; Yeoh, Wei Yi; Zhao, Cang The Journal of the Acoustical Society of America, Vol. 150, Issue 4 https://doi.org/10.1121/10.0006386	journal	October 2021
Visualisation and numerical analysis of laser powder bed fusion under cross-flow Bitharas, I.; Burton, A.; Ross, A. J. Additive Manufacturing, Vol. 37 https://doi.org/10.1016/j.addma.2020.101690	journal	January 2021
Types of spatter and their features and formation mechanisms in laser powder bed fusion additive manufacturing process Young, Zachary A.; Guo, Qilin; Parab, Niranjan D. Additive Manufacturing, Vol. 36 https://doi.org/10.1016/j.addma.2020.101438	journal	December 2020
Modelling the complex evaporated gas flow and its impact on particle spattering during laser powder bed fusion Jakumeit, Jürgen; Zheng, Gongyuan; Laqua, Romuald Additive Manufacturing, Vol. 47 https://doi.org/10.1016/j.addma.2021.102332	journal	November 2021

Similar Records

High-speed Synchrotron X-ray Imaging of Laser Powder Bed Fusion Process

Journal Article · 2019 · Synchrotron Radiation News · OSTI ID:1839956

Parab, Niranjan D.; Zhao, Cang; Cunningham, Ross; +12 more

Multi phenomena melt pool sensor data fusion for enhanced process monitoring of laser powder bed fusion additive manufacturing

Journal Article · 2022 · Materials & Design · OSTI ID:1977418

Gaikwad, Aniruddha; Williams, Richard J.; de Winton, Harry; +4 more

In situ synchrotron X-ray imaging of 4140 steel laser powder bed fusion

Journal Article · 2019 · Materialia · OSTI ID:1774504

Bobel, Andrew; Hector, Louis G.; Chelladurai, Isaac; +9 more

Related Subjects

42 ENGINEERING
47 OTHER INSTRUMENTATION
36 MATERIALS SCIENCE
Acoustics
Photodiodes
X-ray imaging
Synchrotron radiation
Electronic signals
Lasers

Title: A laser powder bed fusion system for operando synchrotron x-ray imaging and correlative diagnostic experiments at the Stanford Synchrotron Radiation Lightsource

Citation Formats

References (50)

Similar Records

Related Subjects