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Title: Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges

Abstract

The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In this study, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.

Authors:
 [1];  [1];  [1];  [1];  [1];  [1];  [1]
  1. Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
Publication Date:
Research Org.:
Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1260471
Report Number(s):
LLNL-JRNL-676941
Journal ID: ISSN 1931-9401 APRPG5
Grant/Contract Number:  
AC52-07NA27344
Resource Type:
Journal Article: Accepted Manuscript
Journal Name:
Applied Physics Reviews
Additional Journal Information:
Journal Volume: 2; Journal Issue: 4; Journal ID: ISSN 1931-9401 APRPG5
Publisher:
American Institute of Physics
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING; 36 MATERIALS SCIENCE; powders; powder metallurgy; manufacturing; materials properties; experiment design

Citation Formats

King, W. E., Anderson, A. T., Ferencz, R. M., Hodge, N. E., Kamath, C., Khairallah, S. A., and Rubencik, A. M. Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges. United States: N. p., 2015. Web. doi:10.1063/1.4937809.
King, W. E., Anderson, A. T., Ferencz, R. M., Hodge, N. E., Kamath, C., Khairallah, S. A., & Rubencik, A. M. Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges. United States. https://doi.org/10.1063/1.4937809
King, W. E., Anderson, A. T., Ferencz, R. M., Hodge, N. E., Kamath, C., Khairallah, S. A., and Rubencik, A. M. 2015. "Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges". United States. https://doi.org/10.1063/1.4937809. https://www.osti.gov/servlets/purl/1260471.
@article{osti_1260471,
title = {Laser powder bed fusion additive manufacturing of metals; physics, computational, and materials challenges},
author = {King, W. E. and Anderson, A. T. and Ferencz, R. M. and Hodge, N. E. and Kamath, C. and Khairallah, S. A. and Rubencik, A. M.},
abstractNote = {The production of metal parts via laser powder bed fusion additive manufacturing is growing exponentially. However, the transition of this technology from production of prototypes to production of critical parts is hindered by a lack of confidence in the quality of the part. Confidence can be established via a fundamental understanding of the physics of the process. It is generally accepted that this understanding will be increasingly achieved through modeling and simulation. However, there are significant physics, computational, and materials challenges stemming from the broad range of length and time scales and temperature ranges associated with the process. In this study, we review the current state of the art and describe the challenges that need to be met to achieve the desired fundamental understanding of the physics of the process.},
doi = {10.1063/1.4937809},
url = {https://www.osti.gov/biblio/1260471}, journal = {Applied Physics Reviews},
issn = {1931-9401 APRPG5},
number = 4,
volume = 2,
place = {United States},
year = {Tue Dec 29 00:00:00 EST 2015},
month = {Tue Dec 29 00:00:00 EST 2015}
}

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Cited by: 609 works
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Works referencing / citing this record:

Energy Coupling Mechanisms and Scaling Behavior Associated with Laser Powder Bed Fusion Additive Manufacturing
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Laser‐Induced Keyhole Defect Dynamics during Metal Additive Manufacturing
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Uncertainty quantification and management in additive manufacturing: current status, needs, and opportunities
journal, July 2017


Gaussian process-based surrogate modeling framework for process planning in laser powder-bed fusion additive manufacturing of 316L stainless steel
journal, September 2017


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Residual stress prediction in selective laser melting: A critical review of simulation strategies
journal, August 2019


The third Sandia fracture challenge: predictions of ductile fracture in additively manufactured metal
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A Perspective on Solid-State Additive Manufacturing of Aluminum Matrix Composites Using MELD
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Rapid fabrication and thermoelectric performance of SnTe via non-equilibrium laser 3D printing
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Process-Structure Linkages Using a Data Science Approach: Application to Simulated Additive Manufacturing Data
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Phase Fraction and Evolution of Additively Manufactured (AM) 15-5 Stainless Steel and Inconel 625 AM-Bench Artifacts
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