Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction

Zhao, Cang; Fezzaa, Kamel; Cunningham, Ross W.; Wen, Haidan; De Carlo, Francesco; Chen, Lianyi; Rollett, Anthony D.; Sun, Tao

doi:10.1038/s41598-017-03761-2

Title: Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction

Abstract

Here, we employ the high-speed synchrotron hard X-ray imaging and diffraction techniques to monitor the laser powder bed fusion (LPBF) process of Ti-6Al-4V in situ and in real time. We demonstrate that many scientifically and technologically significant phenomena in LPBF, including melt pool dynamics, powder ejection, rapid solidification, and phase transformation, can be probed with unprecedented spatial and temporal resolutions. In particular, the keyhole pore formation is experimentally revealed with high spatial and temporal resolutions. The solidification rate is quantitatively measured, and the slowly decrease in solidification rate during the relatively steady state could be a manifestation of the recalescence phenomenon. The high-speed diffraction enables a reasonable estimation of the cooling rate and phase transformation rate, and the diffusionless transformation from β to α’ phase is evident. The data present here will facilitate the understanding of dynamics and kinetics in metal LPBF process, and the experiment platform established will undoubtedly become a new paradigm for future research and development of metal additive manufacturing.

Authors:

^[1]; Fezzaa, Kamel ^[1];

^[2]; Wen, Haidan ^[1]; De Carlo, Francesco ^[1];

^[3]; Rollett, Anthony D. ^[2]; Sun, Tao ^[1]

Argonne National Lab. (ANL), Argonne, IL (United States)
Carnegie Mellon Univ., Pittsburgh, PA (United States)
Missouri Univ. of Science and Technology, Rolla, MO (United States)

Publication Date:: Thu Jun 15 00:00:00 EDT 2017

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

Sponsoring Org.:: USDOE National Nuclear Security Administration (NNSA); USDOE Office of Science (SC), Basic Energy Sciences (BES)

OSTI Identifier:: 1374441

Grant/Contract Number:: AC02-06CH11357

Resource Type:: Accepted Manuscript

Journal Name:: Scientific Reports

Additional Journal Information:: Journal Volume: 7; Journal Issue: 1; Journal ID: ISSN 2045-2322

Publisher:: Nature Publishing Group

Country of Publication:: United States

Language:: English

Subject:: 46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND TECHNOLOGY; 73 NUCLEAR PHYSICS AND RADIATION PHYSICS; applied physics; characterization and analytical techniques; mechanical engineering

Citation Formats


                    Zhao, Cang, Fezzaa, Kamel, Cunningham, Ross W., Wen, Haidan, De Carlo, Francesco, Chen, Lianyi, Rollett, Anthony D., and Sun, Tao. Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction.  United States: N. p., 2017. 
Web.  doi:10.1038/s41598-017-03761-2.

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                    Zhao, Cang, Fezzaa, Kamel, Cunningham, Ross W., Wen, Haidan, De Carlo, Francesco, Chen, Lianyi, Rollett, Anthony D., & Sun, Tao. Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction.  United States.  https://doi.org/10.1038/s41598-017-03761-2

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                    Zhao, Cang, Fezzaa, Kamel, Cunningham, Ross W., Wen, Haidan, De Carlo, Francesco, Chen, Lianyi, Rollett, Anthony D., and Sun, Tao. Thu .  
"Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction".  United States.  https://doi.org/10.1038/s41598-017-03761-2.  https://www.osti.gov/servlets/purl/1374441.

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@article{osti_1374441,

  title        = {Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction},

  author       = {Zhao, Cang and Fezzaa, Kamel and Cunningham, Ross W. and Wen, Haidan and De Carlo, Francesco and Chen, Lianyi and Rollett, Anthony D. and Sun, Tao},

  abstractNote = {Here, we employ the high-speed synchrotron hard X-ray imaging and diffraction techniques to monitor the laser powder bed fusion (LPBF) process of Ti-6Al-4V in situ and in real time. We demonstrate that many scientifically and technologically significant phenomena in LPBF, including melt pool dynamics, powder ejection, rapid solidification, and phase transformation, can be probed with unprecedented spatial and temporal resolutions. In particular, the keyhole pore formation is experimentally revealed with high spatial and temporal resolutions. The solidification rate is quantitatively measured, and the slowly decrease in solidification rate during the relatively steady state could be a manifestation of the recalescence phenomenon. The high-speed diffraction enables a reasonable estimation of the cooling rate and phase transformation rate, and the diffusionless transformation from β to α’ phase is evident. The data present here will facilitate the understanding of dynamics and kinetics in metal LPBF process, and the experiment platform established will undoubtedly become a new paradigm for future research and development of metal additive manufacturing.},

  doi          = {10.1038/s41598-017-03761-2},

  journal      = {Scientific Reports},

  number       = 1,

  volume       = 7,

  place        = {United States},

  year         = {Thu Jun 15 00:00:00 EDT 2017},

  month        = {Thu Jun 15 00:00:00 EDT 2017}

}

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Kenel, C.; Grolimund, D.; Li, X.
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A laser powder bed fusion system for in situ x-ray diffraction with high-energy synchrotron radiation
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Uhlmann, Eckart; Krohmer, Erwin; Schmeiser, Felix
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Dynamics of pore formation during laser powder bed fusion additive manufacturing
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Martin, Aiden A.; Calta, Nicholas P.; Khairallah, Saad A.
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DOI: 10.1038/s41467-019-10009-2

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International Union of Crystallography (IUCr)
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Title: Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction

Abstract

Citation Formats

Dynamics of keyhole and molten pool in laser welding journal, December 1998

Computer-Aided Design for Additive Manufacturing of Cellular Structures journal, January 2007

The metallurgy and processing science of metal additive manufacturing journal, March 2016

Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing journal, December 2014

Dissipation‐theory treatment of the transition from diffusion‐controlled to diffusionless solidification journal, September 1983

Denudation of metal powder layers in laser powder bed fusion processes journal, August 2016

Mesoscopic simulation model of selective laser melting of stainless steel powder journal, November 2014

Evaluating the Effect of Processing Parameters on Porosity in Electron Beam Melted Ti-6Al-4V via Synchrotron X-ray Microtomography journal, January 2016

Characterization of nanoporous structures: from three dimensions to two dimensions journal, January 2016

Experimental and numerical investigation of temperature distribution and melt pool geometry during pulsed laser welding of Ti6Al4V alloy journal, July 2014

Transient x-ray diffraction with simultaneous imaging under high strain-rate loading journal, November 2014

Multiscale Modeling of Powder Bed–Based Additive Manufacturing journal, July 2016

Melt pool and keyhole behaviour analysis for deep penetration laser welding journal, October 2010

Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges journal, December 2015

Grain Nucleation and Growth During Phase Transformations journal, November 2002

Consolidation phenomena in laser and powder-bed based layered manufacturing journal, January 2007

Correlation between solidification parameters and weld microstructures journal, January 1989

Grain Nucleation and Growth During Phase Transformations journal, November 2002

Microstructural Control of Additively Manufactured Metallic Materials journal, July 2016

Heat Flow during Rapid Solidification of Undercooled Metal Droplets journal, February 1982

Additive manufacturing of strong and ductile Ti–6Al–4V by selective laser melting via in situ martensite decomposition journal, February 2015

Physical Aspects of Process Control in Selective Laser Sintering of Metals journal, October 2003

Metallic materials for 3D printing journal, October 2016

Phase transformation dynamics during welding of Ti–6Al–4V journal, June 2004

Metallic materials for 3D printing journal, October 2016

Correlation between solidification parameters and weld microstructures journal, January 1989

Additive Manufacturing Technologies book, January 2010

Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges journal, December 2015

Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones journal, April 2016

Rapid manufacturing of metal components by laser forming journal, October 2006

Fast Compressive Tracking journal, October 2014

Simultaneous X-ray diffraction and phase-contrast imaging for investigating material deformation mechanisms during high-rate loading journal, January 2015

Synchrotron-Based X-ray Microtomography Characterization of the Effect of Processing Variables on Porosity Formation in Laser Power-Bed Additive Manufacturing of Ti-6Al-4V journal, January 2017

The role of recoil pressure in energy balance during laser materials processing journal, September 1997

Dynamics of keyhole and molten pool in laser welding journal, December 1998

Denudation of metal powder layers in laser powder bed fusion processes journal, August 2016

Recyclability Study on Inconel 718 and Ti-6Al-4V Powders for Use in Electron Beam Melting journal, October 2015

Computer-Aided Design for Additive Manufacturing of Cellular Structures journal, January 2007

Consolidation phenomena in laser and powder-bed based layered manufacturing journal, January 2007

HiSPoD : a program for high-speed polychromatic X-ray diffraction experiments and data analysis on polycrystalline samples journal, June 2016

Phase transformations during cooling in α+β titanium alloys journal, March 1998

Ultrafast X-Ray Phase-Contrast Imaging of the Initial Coalescence Phase of Two Water Droplets journal, March 2008

Laser additive manufacturing of metallic components: materials, processes and mechanisms journal, May 2012

Spatially resolved X-ray diffraction phase mapping and α → β → α transformation kinetics in the heat-affected zone of commercially pure titanium arc welds journal, November 1998

Rapid solidification journal, January 1982

Transient x-ray diffraction with simultaneous imaging under high strain-rate loading journal, November 2014

Microstructure and texture evolution during solidification processing of Ti–6Al–4V journal, April 2003

The phase-field method: simulation of alloy dendritic solidification during recalescence journal, March 1996

Evaluating the Effect of Processing Parameters on Porosity in Electron Beam Melted Ti-6Al-4V via Synchrotron X-ray Microtomography journal, January 2016

The role of recoil pressure in energy balance during laser materials processing journal, September 1997

The metallurgy and processing science of metal additive manufacturing journal, March 2016

Metal Additive Manufacturing: A Review journal, April 2014

Physical Aspects of Process Control in Selective Laser Sintering of Metals journal, October 2003

Detection technique for transition between deep penetration mode and shallow penetration mode in CO 2 laser welding of metals journal, October 2000

Critical assessment of the fatigue performance of additively manufactured Ti–6Al–4V and perspective for future research journal, April 2016

Experimental and numerical investigation of temperature distribution and melt pool geometry during pulsed laser welding of Ti6Al4V alloy journal, July 2014

Detection technique for transition between deep penetration mode and shallow penetration mode in CO 2 laser welding of metals journal, October 2000

Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones journal, April 2016

Spatially resolved X-ray diffraction phase mapping and α → β → α transformation kinetics in the heat-affected zone of commercially pure titanium arc welds journal, November 1998

Rapid manufacturing of metal components by laser forming journal, October 2006

Perspectives on Additive Manufacturing journal, July 2016

Characterization of Metal Powders Used for Additive Manufacturing journal, January 2014

Metal Additive Manufacturing: A Review journal, April 2014

Melt pool and keyhole behaviour analysis for deep penetration laser welding journal, October 2010

Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing journal, December 2014

Mesoscopic simulation model of selective laser melting of stainless steel powder journal, November 2014

Additive manufacturing of strong and ductile Ti–6Al–4V by selective laser melting via in situ martensite decomposition journal, February 2015

A two-dimensional transient model for convection in laser melted pool journal, December 1984

Data analytics approach for melt-pool geometries in metal additive manufacturing text, January 2019

Pore elimination mechanisms during 3D printing of metals journal, July 2019

A comprehensive study on microstructure and tensile behaviour of a selectively laser melted stainless steel journal, May 2018

Evaluation of Corrosion Resistance of Alloy 625 Obtained by Laser Powder Bed Fusion journal, January 2019

Benchmark Study of Thermal Behavior, Surface Topography, and Dendritic Microstructure in Selective Laser Melting of Inconel 625 journal, April 2019

In situ X-ray imaging of defect and molten pool dynamics in laser additive manufacturing journal, April 2018

Ultrafast X-ray imaging of laser–metal additive manufacturing processes text, January 2018

Additive manufacturing of CuCr1Zr by development of a gas atomization and laser powder bed fusion routine text, January 2020

Revealing particle-scale powder spreading dynamics in powder-bed-based additive manufacturing process by high-speed x-ray imaging journal, October 2018

Dynamics of keyhole and molten pool in laser welding
journal, December 1998

Computer-Aided Design for Additive Manufacturing of Cellular Structures
journal, January 2007

The metallurgy and processing science of metal additive manufacturing
journal, March 2016

Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing
journal, December 2014

Dissipation‐theory treatment of the transition from diffusion‐controlled to diffusionless solidification
journal, September 1983

Denudation of metal powder layers in laser powder bed fusion processes
journal, August 2016

Mesoscopic simulation model of selective laser melting of stainless steel powder
journal, November 2014

Evaluating the Effect of Processing Parameters on Porosity in Electron Beam Melted Ti-6Al-4V via Synchrotron X-ray Microtomography
journal, January 2016

Characterization of nanoporous structures: from three dimensions to two dimensions
journal, January 2016

Experimental and numerical investigation of temperature distribution and melt pool geometry during pulsed laser welding of Ti6Al4V alloy
journal, July 2014

Transient x-ray diffraction with simultaneous imaging under high strain-rate loading
journal, November 2014

Multiscale Modeling of Powder Bed–Based Additive Manufacturing
journal, July 2016

Melt pool and keyhole behaviour analysis for deep penetration laser welding
journal, October 2010

Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges
journal, December 2015

Grain Nucleation and Growth During Phase Transformations
journal, November 2002

Consolidation phenomena in laser and powder-bed based layered manufacturing
journal, January 2007

Correlation between solidification parameters and weld microstructures
journal, January 1989

Grain Nucleation and Growth During Phase Transformations
journal, November 2002

Microstructural Control of Additively Manufactured Metallic Materials
journal, July 2016

Heat Flow during Rapid Solidification of Undercooled Metal Droplets
journal, February 1982

Additive manufacturing of strong and ductile Ti–6Al–4V by selective laser melting via in situ martensite decomposition
journal, February 2015

Physical Aspects of Process Control in Selective Laser Sintering of Metals
journal, October 2003

Metallic materials for 3D printing
journal, October 2016

Phase transformation dynamics during welding of Ti–6Al–4V
journal, June 2004

Metallic materials for 3D printing
journal, October 2016

Correlation between solidification parameters and weld microstructures
journal, January 1989

Additive Manufacturing Technologies
book, January 2010

Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges
journal, December 2015

Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones
journal, April 2016

Rapid manufacturing of metal components by laser forming
journal, October 2006

Fast Compressive Tracking
journal, October 2014

Simultaneous X-ray diffraction and phase-contrast imaging for investigating material deformation mechanisms during high-rate loading
journal, January 2015

Synchrotron-Based X-ray Microtomography Characterization of the Effect of Processing Variables on Porosity Formation in Laser Power-Bed Additive Manufacturing of Ti-6Al-4V
journal, January 2017

The role of recoil pressure in energy balance during laser materials processing
journal, September 1997

Dynamics of keyhole and molten pool in laser welding
journal, December 1998

Denudation of metal powder layers in laser powder bed fusion processes
journal, August 2016

Recyclability Study on Inconel 718 and Ti-6Al-4V Powders for Use in Electron Beam Melting
journal, October 2015

Computer-Aided Design for Additive Manufacturing of Cellular Structures
journal, January 2007

Consolidation phenomena in laser and powder-bed based layered manufacturing
journal, January 2007

HiSPoD : a program for high-speed polychromatic X-ray diffraction experiments and data analysis on polycrystalline samples
journal, June 2016

Phase transformations during cooling in α+β titanium alloys
journal, March 1998

Ultrafast X-Ray Phase-Contrast Imaging of the Initial Coalescence Phase of Two Water Droplets
journal, March 2008

Laser additive manufacturing of metallic components: materials, processes and mechanisms
journal, May 2012

Spatially resolved X-ray diffraction phase mapping and α → β → α transformation kinetics in the heat-affected zone of commercially pure titanium arc welds
journal, November 1998

Rapid solidification
journal, January 1982

Transient x-ray diffraction with simultaneous imaging under high strain-rate loading
journal, November 2014

Microstructure and texture evolution during solidification processing of Ti–6Al–4V
journal, April 2003

The phase-field method: simulation of alloy dendritic solidification during recalescence
journal, March 1996

Evaluating the Effect of Processing Parameters on Porosity in Electron Beam Melted Ti-6Al-4V via Synchrotron X-ray Microtomography
journal, January 2016

The role of recoil pressure in energy balance during laser materials processing
journal, September 1997

The metallurgy and processing science of metal additive manufacturing
journal, March 2016

Metal Additive Manufacturing: A Review
journal, April 2014

Physical Aspects of Process Control in Selective Laser Sintering of Metals
journal, October 2003

Detection technique for transition between deep penetration mode and shallow penetration mode in CO ₂ laser welding of metals
journal, October 2000

Critical assessment of the fatigue performance of additively manufactured Ti–6Al–4V and perspective for future research
journal, April 2016

Experimental and numerical investigation of temperature distribution and melt pool geometry during pulsed laser welding of Ti6Al4V alloy
journal, July 2014

Detection technique for transition between deep penetration mode and shallow penetration mode in CO ₂ laser welding of metals
journal, October 2000

Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones
journal, April 2016

Spatially resolved X-ray diffraction phase mapping and α → β → α transformation kinetics in the heat-affected zone of commercially pure titanium arc welds
journal, November 1998

Rapid manufacturing of metal components by laser forming
journal, October 2006

Perspectives on Additive Manufacturing
journal, July 2016

Characterization of Metal Powders Used for Additive Manufacturing
journal, January 2014

Metal Additive Manufacturing: A Review
journal, April 2014

Melt pool and keyhole behaviour analysis for deep penetration laser welding
journal, October 2010

Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing
journal, December 2014

Mesoscopic simulation model of selective laser melting of stainless steel powder
journal, November 2014

Additive manufacturing of strong and ductile Ti–6Al–4V by selective laser melting via in situ martensite decomposition
journal, February 2015

A two-dimensional transient model for convection in laser melted pool
journal, December 1984

Data analytics approach for melt-pool geometries in metal additive manufacturing
text, January 2019

Pore elimination mechanisms during 3D printing of metals
journal, July 2019

A comprehensive study on microstructure and tensile behaviour of a selectively laser melted stainless steel
journal, May 2018

Evaluation of Corrosion Resistance of Alloy 625 Obtained by Laser Powder Bed Fusion
journal, January 2019

Benchmark Study of Thermal Behavior, Surface Topography, and Dendritic Microstructure in Selective Laser Melting of Inconel 625
journal, April 2019

In situ X-ray imaging of defect and molten pool dynamics in laser additive manufacturing
journal, April 2018

Ultrafast X-ray imaging of laser–metal additive manufacturing processes
text, January 2018

Additive manufacturing of CuCr1Zr by development of a gas atomization and laser powder bed fusion routine
text, January 2020

Revealing particle-scale powder spreading dynamics in powder-bed-based additive manufacturing process by high-speed x-ray imaging
journal, October 2018

Data analytics approach for melt-pool geometries in metal additive manufacturing
journal, October 2019

A comprehensive study on microstructure and tensile behaviour of a selectively laser melted stainless steel
journal, May 2018

Evaluation for multiple processing parameters in selective laser melting based on an integration of mesoscale simulation and experiment method
journal, January 2020