A laser powder bed fusion system for operando synchrotron x-ray imaging and correlative diagnostic experiments at the Stanford Synchrotron Radiation Lightsource
Abstract
Laser powder bed fusion (LPBF) is a highly dynamic multi-physics process used for the additive manufacturing (AM) of metal components. Improving process understanding and validating predictive computational models require high-fidelity diagnostics capable of capturing data in challenging environments. Synchrotron x-ray techniques play a vital role in the validation process as they are the only in situ diagnostic capable of imaging sub-surface melt pool dynamics and microstructure evolution during LPBF-AM. In this article, a laboratory scale system designed to mimic LPBF process conditions while operating at a synchrotron facility is described. The system is implemented with process accurate atmospheric conditions, including an air knife for active vapor plume removal. Significantly, the chamber also incorporates a diagnostic sensor suite that monitors emitted optical, acoustic, and electronic signals during laser processing with coincident x-ray imaging. The addition of the sensor suite enables validation of these industrially compatible single point sensors by detecting pore formation and spatter events and directly correlating the events with changes in the detected signal. Experiments in the Ti–6Al–4V alloy performed at the Stanford Synchrotron Radiation Lightsource using the system are detailed with sufficient sampling rates to probe melt pool dynamics. X-ray imaging captures melt pool dynamics at frame ratesmore »
- Authors:
-
- Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
- SLAC National Accelerator Lab., Menlo Park, CA (United States)
- Publication Date:
- Research Org.:
- SLAC National Accelerator Laboratory (SLAC), Menlo Park, CA (United States); Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
- Sponsoring Org.:
- USDOE National Nuclear Security Administration (NNSA); USDOE Laboratory Directed Research and Development (LDRD) Program; USDOE Office of Science (SC), Basic Energy Sciences (BES)
- OSTI Identifier:
- 1882689
- Alternate Identifier(s):
- OSTI ID: 1860528; OSTI ID: 1880936
- Report Number(s):
- LLNL-JRNL-829176
Journal ID: ISSN 0034-6748; 21-ERD-008; TRN: US2307933
- Grant/Contract Number:
- AC02-76SF00515; AC52-07NA27344; 21-ERD-008
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Review of Scientific Instruments
- Additional Journal Information:
- Journal Volume: 93; Journal Issue: 4; Journal ID: ISSN 0034-6748
- Publisher:
- American Institute of Physics (AIP)
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 42 ENGINEERING; 47 OTHER INSTRUMENTATION; 36 MATERIALS SCIENCE; acoustics; photodiodes; x-ray imaging; synchrotron radiation; electronic signals; lasers
Citation Formats
Martin, Aiden A., Wang, Jenny, DePond, Philip J., Strantza, Maria, Forien, Jean-Baptiste, Gorgannejad, Sanam, Guss, Gabriel M., Thampy, Vivek, Fong, Anthony Y., Weker, Johanna Nelson, Stone, Kevin H., Tassone, Christopher J., Matthews, Manyalibo J., and Calta, Nicholas P. A laser powder bed fusion system for operando synchrotron x-ray imaging and correlative diagnostic experiments at the Stanford Synchrotron Radiation Lightsource. United States: N. p., 2022.
Web. doi:10.1063/5.0080724.
Martin, Aiden A., Wang, Jenny, DePond, Philip J., Strantza, Maria, Forien, Jean-Baptiste, Gorgannejad, Sanam, Guss, Gabriel M., Thampy, Vivek, Fong, Anthony Y., Weker, Johanna Nelson, Stone, Kevin H., Tassone, Christopher J., Matthews, Manyalibo J., & Calta, Nicholas P. A laser powder bed fusion system for operando synchrotron x-ray imaging and correlative diagnostic experiments at the Stanford Synchrotron Radiation Lightsource. United States. https://doi.org/10.1063/5.0080724
Martin, Aiden A., Wang, Jenny, DePond, Philip J., Strantza, Maria, Forien, Jean-Baptiste, Gorgannejad, Sanam, Guss, Gabriel M., Thampy, Vivek, Fong, Anthony Y., Weker, Johanna Nelson, Stone, Kevin H., Tassone, Christopher J., Matthews, Manyalibo J., and Calta, Nicholas P. Fri .
"A laser powder bed fusion system for operando synchrotron x-ray imaging and correlative diagnostic experiments at the Stanford Synchrotron Radiation Lightsource". United States. https://doi.org/10.1063/5.0080724. https://www.osti.gov/servlets/purl/1882689.
@article{osti_1882689,
title = {A laser powder bed fusion system for operando synchrotron x-ray imaging and correlative diagnostic experiments at the Stanford Synchrotron Radiation Lightsource},
author = {Martin, Aiden A. and Wang, Jenny and DePond, Philip J. and Strantza, Maria and Forien, Jean-Baptiste and Gorgannejad, Sanam and Guss, Gabriel M. and Thampy, Vivek and Fong, Anthony Y. and Weker, Johanna Nelson and Stone, Kevin H. and Tassone, Christopher J. and Matthews, Manyalibo J. and Calta, Nicholas P.},
abstractNote = {Laser powder bed fusion (LPBF) is a highly dynamic multi-physics process used for the additive manufacturing (AM) of metal components. Improving process understanding and validating predictive computational models require high-fidelity diagnostics capable of capturing data in challenging environments. Synchrotron x-ray techniques play a vital role in the validation process as they are the only in situ diagnostic capable of imaging sub-surface melt pool dynamics and microstructure evolution during LPBF-AM. In this article, a laboratory scale system designed to mimic LPBF process conditions while operating at a synchrotron facility is described. The system is implemented with process accurate atmospheric conditions, including an air knife for active vapor plume removal. Significantly, the chamber also incorporates a diagnostic sensor suite that monitors emitted optical, acoustic, and electronic signals during laser processing with coincident x-ray imaging. The addition of the sensor suite enables validation of these industrially compatible single point sensors by detecting pore formation and spatter events and directly correlating the events with changes in the detected signal. Experiments in the Ti–6Al–4V alloy performed at the Stanford Synchrotron Radiation Lightsource using the system are detailed with sufficient sampling rates to probe melt pool dynamics. X-ray imaging captures melt pool dynamics at frame rates of 20 kHz with a 2 µm pixel resolution, and the coincident diagnostic sensor data are recorded at 470 kHz. Furthermore, this work shows that the current system enables the in situ detection of defects during the LPBF process and permits direct correlation of diagnostic signatures at the exact time of defect formation.},
doi = {10.1063/5.0080724},
journal = {Review of Scientific Instruments},
number = 4,
volume = 93,
place = {United States},
year = {Fri Apr 01 00:00:00 EDT 2022},
month = {Fri Apr 01 00:00:00 EDT 2022}
}
Figures / Tables:
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