Understanding process-microstructure-property relationships in laser powder bed fusion of non-spherical Ti-6Al-4V powder
Abstract
Powder feedstock is a major cost driver in metal additive manufacturing (AM). Replacing the spherical powder with the cost-efficient non-spherical one can reduce the feedstock cost up to 50% and attract more interest to adopt AM in production and new alloy development. Here, for this paper, a comprehensive study was conducted to understand process-microstructure-property relationships in laser powder bed fusion of hydride-dehydride Ti-6Al-4V powder. We demonstrated that variation of laser scan speed had a significant impact on the grain structure, pore evolution and properties compared to laser power. Dynamic X-ray radiography showed that with decreasing scan speed at a constant laser power, a transition from conduction to keyhole mode laser processing occurred, in which a deeper melt pool at lower scan speed intensified texture. In other words, an increase in laser scan speed resulted in formation of the refined prior β grains with shape factor of ~5, lowering the anisotropy. Furthermore, the degree of variant selection was evaluated based on the analyzed texture as a function of laser power and scan speed. With increasing laser scan speed, the dominant α/α boundary type was altered from type 2 to 4 and the degree of variant selection was noticeably decreased. On themore »
- Authors:
-
- Illinois Institute of Technology, Chicago, IL (United States)
- University of California, Los Angeles, CA (United States)
- Carnegie Mellon University, Pittsburgh, PA (United States); Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States). Materials Engineering Division
- Argonne National Laboratory (ANL), Argonne, IL (United States). X-ray Science Division
- Kymera International, Robesonia, PA (United States)
- Carnegie Mellon University, Pittsburgh, PA (United States)
- Publication Date:
- Research Org.:
- Argonne National Laboratory (ANL), Argonne, IL (United States); Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
- Sponsoring Org.:
- USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities (SUF); USDOE National Nuclear Security Administration (NNSA); National Science Foundation (NSF); USDOE Office of Science (SC)
- OSTI Identifier:
- 2281002
- Alternate Identifier(s):
- OSTI ID: 1959854; OSTI ID: 1983730
- Report Number(s):
- LLNL-JRNL-844166
Journal ID: ISSN 1044-5803; 185718
- Grant/Contract Number:
- AC02-06CH11357; AC52-07NA27344; DMR-2050916
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Materials Characterization
- Additional Journal Information:
- Journal Volume: 198; Journal ID: ISSN 1044-5803
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; Additive manufacturing; Texture analysis; Synchrotron X-ray high-speed imaging; variant selection; Hardness; Hydride-dehydride powder; additive manufacturing; texture analysis; synchrotron x-ray high-speed imaging; hardness
Citation Formats
Asherloo, Mohammadreza, Hwang, Junghyun, Leroux, Ryan, Wu, Ziheng, Fezzaa, Kamel, Paliwal, Muktesh, Rollett, Anthony D., and Mostafaei, Amir. Understanding process-microstructure-property relationships in laser powder bed fusion of non-spherical Ti-6Al-4V powder. United States: N. p., 2023.
Web. doi:10.1016/j.matchar.2023.112757.
Asherloo, Mohammadreza, Hwang, Junghyun, Leroux, Ryan, Wu, Ziheng, Fezzaa, Kamel, Paliwal, Muktesh, Rollett, Anthony D., & Mostafaei, Amir. Understanding process-microstructure-property relationships in laser powder bed fusion of non-spherical Ti-6Al-4V powder. United States. https://doi.org/10.1016/j.matchar.2023.112757
Asherloo, Mohammadreza, Hwang, Junghyun, Leroux, Ryan, Wu, Ziheng, Fezzaa, Kamel, Paliwal, Muktesh, Rollett, Anthony D., and Mostafaei, Amir. Sun .
"Understanding process-microstructure-property relationships in laser powder bed fusion of non-spherical Ti-6Al-4V powder". United States. https://doi.org/10.1016/j.matchar.2023.112757. https://www.osti.gov/servlets/purl/2281002.
@article{osti_2281002,
title = {Understanding process-microstructure-property relationships in laser powder bed fusion of non-spherical Ti-6Al-4V powder},
author = {Asherloo, Mohammadreza and Hwang, Junghyun and Leroux, Ryan and Wu, Ziheng and Fezzaa, Kamel and Paliwal, Muktesh and Rollett, Anthony D. and Mostafaei, Amir},
abstractNote = {Powder feedstock is a major cost driver in metal additive manufacturing (AM). Replacing the spherical powder with the cost-efficient non-spherical one can reduce the feedstock cost up to 50% and attract more interest to adopt AM in production and new alloy development. Here, for this paper, a comprehensive study was conducted to understand process-microstructure-property relationships in laser powder bed fusion of hydride-dehydride Ti-6Al-4V powder. We demonstrated that variation of laser scan speed had a significant impact on the grain structure, pore evolution and properties compared to laser power. Dynamic X-ray radiography showed that with decreasing scan speed at a constant laser power, a transition from conduction to keyhole mode laser processing occurred, in which a deeper melt pool at lower scan speed intensified texture. In other words, an increase in laser scan speed resulted in formation of the refined prior β grains with shape factor of ~5, lowering the anisotropy. Furthermore, the degree of variant selection was evaluated based on the analyzed texture as a function of laser power and scan speed. With increasing laser scan speed, the dominant α/α boundary type was altered from type 2 to 4 and the degree of variant selection was noticeably decreased. On the other hand, increasing laser power left the morphology of prior β grains, their size, and the dominant α/α boundary (type 4) unchanged, while the texture and anisotropy were intensified, and the degree of variant selection was slightly decreased. Finally, dependency of surface roughness and microhardness were discussed as a function of laser processing parameters.},
doi = {10.1016/j.matchar.2023.112757},
journal = {Materials Characterization},
number = ,
volume = 198,
place = {United States},
year = {Sun Feb 26 00:00:00 EST 2023},
month = {Sun Feb 26 00:00:00 EST 2023}
}
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