Controlling melt flow by nanoparticles to eliminate surface wave induced surface fluctuation

Qu, Minglei; Guo, Qilin; Escano, Luis I.; Yuan, Jiandong; Hojjatzadeh, S. Mohammad H.; Clark, Samuel J.; Fezzaa, Kamel; Sun, Tao; Chen, Lianyi

doi:10.1016/j.addma.2022.103081

Title: Controlling melt flow by nanoparticles to eliminate surface wave induced surface fluctuation

Journal Article · 13 August 2022 · Additive Manufacturing

DOI: https://doi.org/10.1016/j.addma.2022.103081 · OSTI ID:1894651

Qu, Minglei ^[1]; Guo, Qilin ^[1]; Escano, Luis I. ^[1]; Yuan, Jiandong ^[1]; Hojjatzadeh, S. Mohammad H. ^[1]; Clark, Samuel J. ^[2]; Fezzaa, Kamel ^[1]; Sun, Tao ^[3]; Chen, Lianyi ^[1]

Univ. of Wisconsin, Madison, WI (United States)
Argonne National Lab. (ANL), Lemont, IL (United States)
Argonne National Lab. (ANL), Lemont, IL (United States); Univ. of Virginia, Charlottesville, VA (United States)

The high surface roughness is one of the major challenges encountered in laser metal additive manufacturing (AM) processes, which is closely related to the melt flow behavior. However, how to control the melt flow in laser metal AM processes to improve surface finish is unknown. Here we reveal the effects of nanoparticles on melt flow behavior at every location of melt pool during laser metal AM process for the first time using Al6061 + TiC nanoparticles system and achieve significant improvement of surface finish by using TiC nanoparticles to control the melt flow and damp the surface wave. Based on the in-situ x-ray imaging observation, the surface wave is fully damped after adding TiC nanoparticles, compared with only 56% damping without nanoparticles during LPBF of Al6061. Our in-depth in-situ x-ray imaging analysis and viscosity measurement enable us to identify that nanoparticle-induced increase of viscosity causes the fully damping of the surface wave by (1) increasing the internal fluid friction for more efficient wave amplitude reduction, (2) controlling the melt flow to increase the surface wave number, (3) controlling the melt flow to increase the wave damping time. Furthermore, we also quantified the relative contributions of increasing fluid friction, increasing wave number, and increasing damping time to wave damping, which account for 61%, 25%, and 14%, respectively. Furthermore, our research provides the mechanisms and potential method to address the surface finish challenge in laser metal AM processes.

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

Sponsoring Organization:: National Science Foundation (NSF); USDOE; USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities Division

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 1894651

Journal Information:: Additive Manufacturing, Journal Name: Additive Manufacturing Journal Issue: A Vol. 59; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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