Revealing melt flow instabilities in laser powder bed fusion additive manufacturing of aluminum alloy via in-situ high-speed X-ray imaging
Abstract
Laser metal additive manufacturing technologies enable the fabrication of geometrically and compositionally complex parts unachievable by conventional manufacturing methods. However, the certification and qualification of additively manufactured parts are greatly hindered by the stochastic melt flow instabilities intrinsic to the process, which has not been explicitly revealed by direct observation. Here, we report the mechanisms of the melt flow instabilities in laser powder bed fusion additive manufacturing process revealed by in-situ high-speed high-resolution synchrotron X-ray imaging. Here we identified powder/droplet impact, significant keyhole oscillation, and melting-mode switching as three major mechanisms for causing melt flow instabilities. We demonstrated the detrimental consequences of these instabilities brought to the process, and presented new understanding on the melt flow evolution and keyhole oscillation. This work provides critical insights into process instabilities during laser metal additive manufacturing, which may guide the development of instability mitigation approaches. The results reported here are also important for the development and validation of high-fidelity computational models.
- Authors:
-
- University of Wisconsin, Madison, WI (United States)
- Argonne National Laboratory (ANL), Lemont, IL (United States)
- Publication Date:
- Research Org.:
- Argonne National Lab. (ANL), Argonne, IL (United States)
- Sponsoring Org.:
- USDOE Office of Science (SC), Basic Energy Sciences (BES); National Science Foundation (NSF)
- OSTI Identifier:
- 1970366
- Grant/Contract Number:
- AC02-06CH11357; DMR-1720415
- Resource Type:
- Accepted Manuscript
- Journal Name:
- International Journal of Machine Tools and Manufacture
- Additional Journal Information:
- Journal Volume: 175; Journal ID: ISSN 0890-6955
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; additive manufacturing; laser processing; melt flow; synchrotron X-ray imaging
Citation Formats
Guo, Qilin, Qu, Minglei, Escano, Luis I., Hojjatzadeh, S. H., Young, Zachary, Fezzaa, Kamel, and Chen, Lianyi. Revealing melt flow instabilities in laser powder bed fusion additive manufacturing of aluminum alloy via in-situ high-speed X-ray imaging. United States: N. p., 2022.
Web. doi:10.1016/j.ijmachtools.2022.103861.
Guo, Qilin, Qu, Minglei, Escano, Luis I., Hojjatzadeh, S. H., Young, Zachary, Fezzaa, Kamel, & Chen, Lianyi. Revealing melt flow instabilities in laser powder bed fusion additive manufacturing of aluminum alloy via in-situ high-speed X-ray imaging. United States. https://doi.org/10.1016/j.ijmachtools.2022.103861
Guo, Qilin, Qu, Minglei, Escano, Luis I., Hojjatzadeh, S. H., Young, Zachary, Fezzaa, Kamel, and Chen, Lianyi. Sat .
"Revealing melt flow instabilities in laser powder bed fusion additive manufacturing of aluminum alloy via in-situ high-speed X-ray imaging". United States. https://doi.org/10.1016/j.ijmachtools.2022.103861. https://www.osti.gov/servlets/purl/1970366.
@article{osti_1970366,
title = {Revealing melt flow instabilities in laser powder bed fusion additive manufacturing of aluminum alloy via in-situ high-speed X-ray imaging},
author = {Guo, Qilin and Qu, Minglei and Escano, Luis I. and Hojjatzadeh, S. H. and Young, Zachary and Fezzaa, Kamel and Chen, Lianyi},
abstractNote = {Laser metal additive manufacturing technologies enable the fabrication of geometrically and compositionally complex parts unachievable by conventional manufacturing methods. However, the certification and qualification of additively manufactured parts are greatly hindered by the stochastic melt flow instabilities intrinsic to the process, which has not been explicitly revealed by direct observation. Here, we report the mechanisms of the melt flow instabilities in laser powder bed fusion additive manufacturing process revealed by in-situ high-speed high-resolution synchrotron X-ray imaging. Here we identified powder/droplet impact, significant keyhole oscillation, and melting-mode switching as three major mechanisms for causing melt flow instabilities. We demonstrated the detrimental consequences of these instabilities brought to the process, and presented new understanding on the melt flow evolution and keyhole oscillation. This work provides critical insights into process instabilities during laser metal additive manufacturing, which may guide the development of instability mitigation approaches. The results reported here are also important for the development and validation of high-fidelity computational models.},
doi = {10.1016/j.ijmachtools.2022.103861},
journal = {International Journal of Machine Tools and Manufacture},
number = ,
volume = 175,
place = {United States},
year = {Sat Feb 12 00:00:00 EST 2022},
month = {Sat Feb 12 00:00:00 EST 2022}
}
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