Revealing transient powder-gas interaction in laser powder bed fusion process through multi-physics modeling and high-speed synchrotron x-ray imaging
Abstract
Laser powder bed fusion (LPBF) is an emerging metal additive manufacturing process. The gas-driven powder motions in laser powder bed fusion have significant influence on the build quality. However, the transient powder-gas interaction has not been well understood due to the challenges in quantitative experiment measurements. In this work, the powder-gas interaction for a single pulse laser illuminating on the powder bed is studied. We establish a multi-physics model to simulate the complex liquid/gas flow as well as the gas-driven powder motions, which is substantiated by high-speed synchrotron x-ray imaging. We identify and quantify four characteristic modes of powder-gas interaction in LPBF. The motion of a powder is controlled by one or multiple interaction modes collectively. As revealed by simulations and confirmed by experiments, powders can merge into the molten pool from its rim, be ejected at different divergence angles (powder spattering), or dive into the molten pool to cause significant molten pool fluctuation. Overall, our results provide insights toward the driving forces controlling the dynamic powder behavior, which pave the way for reducing structure defects during the build process.
- Authors:
-
- Univ. of Utah, Salt Lake City, UT (United States)
- Argonne National Lab. (ANL), Lemont, IL (United States); Tsinghua Univ., Beijing (China)
- Argonne National Lab. (ANL), Lemont, IL (United States); Univ. of Virginia, Charlottesville, VA (United States)
- Publication Date:
- Research Org.:
- Argonne National Lab. (ANL), Argonne, IL (United States)
- Sponsoring Org.:
- National Science Foundation (NSF); USDOE Office of Science (SC), Basic Energy Sciences (BES). Scientific User Facilities Division
- OSTI Identifier:
- 1834630
- Grant/Contract Number:
- AC02-06CH11357; CMMI-1933368
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Additive Manufacturing
- Additional Journal Information:
- Journal Volume: 35; Journal ID: ISSN 2214-8604
- Publisher:
- Elsevier
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 36 MATERIALS SCIENCE; Laser powder bed fusion; Powder motion; Powder-gas interaction; Multi-physics modeling; High-speed synchrotron x-ray imaging
Citation Formats
Li, Xuxiao, Zhao, Cang, Sun, Tao, and Tan, Wenda. Revealing transient powder-gas interaction in laser powder bed fusion process through multi-physics modeling and high-speed synchrotron x-ray imaging. United States: N. p., 2020.
Web. doi:10.1016/j.addma.2020.101362.
Li, Xuxiao, Zhao, Cang, Sun, Tao, & Tan, Wenda. Revealing transient powder-gas interaction in laser powder bed fusion process through multi-physics modeling and high-speed synchrotron x-ray imaging. United States. https://doi.org/10.1016/j.addma.2020.101362
Li, Xuxiao, Zhao, Cang, Sun, Tao, and Tan, Wenda. Mon .
"Revealing transient powder-gas interaction in laser powder bed fusion process through multi-physics modeling and high-speed synchrotron x-ray imaging". United States. https://doi.org/10.1016/j.addma.2020.101362. https://www.osti.gov/servlets/purl/1834630.
@article{osti_1834630,
title = {Revealing transient powder-gas interaction in laser powder bed fusion process through multi-physics modeling and high-speed synchrotron x-ray imaging},
author = {Li, Xuxiao and Zhao, Cang and Sun, Tao and Tan, Wenda},
abstractNote = {Laser powder bed fusion (LPBF) is an emerging metal additive manufacturing process. The gas-driven powder motions in laser powder bed fusion have significant influence on the build quality. However, the transient powder-gas interaction has not been well understood due to the challenges in quantitative experiment measurements. In this work, the powder-gas interaction for a single pulse laser illuminating on the powder bed is studied. We establish a multi-physics model to simulate the complex liquid/gas flow as well as the gas-driven powder motions, which is substantiated by high-speed synchrotron x-ray imaging. We identify and quantify four characteristic modes of powder-gas interaction in LPBF. The motion of a powder is controlled by one or multiple interaction modes collectively. As revealed by simulations and confirmed by experiments, powders can merge into the molten pool from its rim, be ejected at different divergence angles (powder spattering), or dive into the molten pool to cause significant molten pool fluctuation. Overall, our results provide insights toward the driving forces controlling the dynamic powder behavior, which pave the way for reducing structure defects during the build process.},
doi = {10.1016/j.addma.2020.101362},
journal = {Additive Manufacturing},
number = ,
volume = 35,
place = {United States},
year = {Mon Jun 15 00:00:00 EDT 2020},
month = {Mon Jun 15 00:00:00 EDT 2020}
}
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