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

Khairallah, Saad A.; Anderson, Andrew T.; Rubenchik, Alexander; King, Wayne E.

doi:10.1016/j.actamat.2016.02.014

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

Journal Article · Tue Feb 23 00:00:00 EST 2016 · Acta Materialia

DOI:https://doi.org/10.1016/j.actamat.2016.02.014· OSTI ID:1262168

Khairallah, Saad A. ^[1]; Anderson, Andrew T. ^[1]; Rubenchik, Alexander ^[1]; King, Wayne E. ^[1]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)

Our study demonstrates the significant effect of the recoil pressure and Marangoni convection in laser powder bed fusion (L-PBF) of 316L stainless steel. A three-dimensional high fidelity powder-scale model reveals how the strong dynamical melt flow generates pore defects, material spattering (sparking), and denudation zones. The melt track is divided into three sections: a topological depression, a transition and a tail region, each being the location of specific physical effects. The inclusion of laser ray-tracing energy deposition in the powder-scale model improves over traditional volumetric energy deposition. It enables partial particle melting, which impacts pore defects in the denudation zone. Different pore formation mechanisms are observed at the edge of a scan track, at the melt pool bottom (during collapse of the pool depression), and at the end of the melt track (during laser power ramp down). Finally, we discuss remedies to these undesirable pores are discussed. The results are validated against the experiments and the sensitivity to laser absorptivity.

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Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC52-07NA27344; 13-SI-002

OSTI ID:: 1262168

Alternate ID(s):: OSTI ID: 1352945

Report Number(s):: LLNL-JRNL-676495

Journal Information:: Acta Materialia, Vol. 108, Issue C; ISSN 1359-6454

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 1398 works

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Thermoelectric magnetohydrodynamic control of melt pool dynamics and microstructure evolution in additive manufacturing Kao, A.; Gan, T.; Tonry, C. Philosophical Transactions of the Royal Society A: Mathematical, Physical and Engineering Sciences, Vol. 378, Issue 2171 https://doi.org/10.1098/rsta.2019.0249	journal	April 2020
Surface deformations in dynamic thermocapillary convection under partial slip Kowal, Katarzyna N.; Davis, Stephen H.; Voorhees, Peter W. Physical Review E, Vol. 100, Issue 2 https://doi.org/10.1103/physreve.100.022802	journal	August 2019
Investigation of the anisotropic cyclic damage behavior of selective laser melted AISI 316L stainless steel Stern, Felix; Kleinhorst, Jan; Tenkamp, Jochen Fatigue & Fracture of Engineering Materials & Structures, Vol. 42, Issue 11 https://doi.org/10.1111/ffe.13029	journal	February 2019
In-Process Monitoring of Material Cross-Contamination Defects in Laser Powder Bed Fusion Montazeri, Mohammad; Yavari, Reza; Rao, Prahalada Journal of Manufacturing Science and Engineering, Vol. 140, Issue 11 https://doi.org/10.1115/1.4040543	journal	July 2018
Layerwise Anomaly Detection in Laser Powder-Bed Fusion Metal Additive Manufacturing Mahmoudi, Mohamad; Ezzat, Ahmed Aziz; Elwany, Alaa Journal of Manufacturing Science and Engineering, Vol. 141, Issue 3 https://doi.org/10.1115/1.4042108	journal	January 2019
A Review of Model Inaccuracy and Parameter Uncertainty in Laser Powder Bed Fusion Models and Simulations Moges, Tesfaye; Ameta, Gaurav; Witherell, Paul Journal of Manufacturing Science and Engineering, Vol. 141, Issue 4 https://doi.org/10.1115/1.4042789	journal	February 2019
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On the possibility of steady-state solutions application to describe a thermal state of parts fabricated by selective laser sintering Kakhramanov, R. M.; Knyazeva, A. G.; Rabinskiy, L. N. High Temperature, Vol. 55, Issue 5 https://doi.org/10.1134/s0018151x1705008x	journal	September 2017
Numerical simulation of selective laser melting with local powder shrinkage using FEM with the refined mesh Gordeev, Georgiy A.; Ankudinov, Vladimir; Kharanzhevskiy, Evgeny V. The European Physical Journal Special Topics, Vol. 229, Issue 2-3 https://doi.org/10.1140/epjst/e2019-900100-6	journal	February 2020
3D Thermal Finite Element Analysis of the SLM 316L Parts with Microstructural Correlations He, Ketai; Zhao, Xue Complexity, Vol. 2018 https://doi.org/10.1155/2018/6910187	journal	October 2018
Formation of SS316L Single Tracks in Micro Selective Laser Melting: Surface, Geometry, and Defects Hu, Zhiheng; Nagarajan, Balasubramanian; Song, Xu Advances in Materials Science and Engineering, Vol. 2019 https://doi.org/10.1155/2019/9451406	journal	January 2019
Finite Element Analysis of Thermal Stress and Thermal Deformation in Typical Part during SLM Bian, Peiying; Shao, Xiaodong; Du, Jingli Applied Sciences, Vol. 9, Issue 11 https://doi.org/10.3390/app9112231	journal	May 2019
A Short Review on the Microstructure, Transformation Behavior and Functional Properties of NiTi Shape Memory Alloys Fabricated by Selective Laser Melting Wang, Xiebin; Kustov, Sergey; Van Humbeeck, Jan Materials, Vol. 11, Issue 9 https://doi.org/10.3390/ma11091683	journal	September 2018
Research and Optimization of Surface Roughness in Milling of SLM Semi-Finished Parts Manufactured by Using the Different Laser Scanning Speed Matras, Andrzej Materials, Vol. 13, Issue 1 https://doi.org/10.3390/ma13010009	journal	December 2019
Characterization of 17-4PH Single Tracks Produced at Different Parametric Conditions towards Increased Productivity of LPBF Systems—The Effect of Laser Power and Spot Size Upscaling Makoana, Nkutwane; Yadroitsava, Ina; Möller, Heinrich Metals, Vol. 8, Issue 7 https://doi.org/10.3390/met8070475	journal	June 2018
Corrosion Behavior of Selectively Laser Melted CoCrFeMnNi High Entropy Alloy Ren, Jie; Mahajan, Chaitanya; Liu, Liang Metals, Vol. 9, Issue 10 https://doi.org/10.3390/met9101029	journal	September 2019
Process-Structure-Properties-Performance Modeling for Selective Laser Melting Pinomaa, Tatu; Yashchuk, Ivan; Lindroos, Matti Metals, Vol. 9, Issue 11 https://doi.org/10.3390/met9111138	journal	October 2019
Development of Bulk Metallic Glass Matrix Composites (BMGMC) by Additive Manufacturing: Modelling and Simulation – A Review: Part A Rafique, Muhammad Musaddique Ali; Niezgoda, Stephen; Brandt, Milan Advanced Materials Research, Vol. 1154 https://doi.org/10.4028/www.scientific.net/amr.1154.1	journal	June 2019
Effect of Powder Type and Particles Size on Microstructure of Selective Laser Sintered Parts Jankus, Simonas Mindaugas; Bendikiene, Regita Key Engineering Materials, Vol. 799 https://doi.org/10.4028/www.scientific.net/kem.799.252	journal	April 2019
Inferring 3D Ellipsoids based on Cross-Sectional Images with Applications to Porosity Control of Additive Manufacturing Wu, Jianguo; Yuan, Yuan; Gong, Haijun Taylor & Francis https://doi.org/10.6084/m9.figshare.5736816.v1	text	January 2017
S𝔸𝕄PLE: A Software Suite to Predict Consolidation and Microstructure for Powder Bed Fusion Additive Manufacturing Markl, Matthias; Rausch, Alexander M.; Küng, Vera E. Advanced Engineering Materials, Vol. 22, Issue 9 https://doi.org/10.1002/adem.201901270	journal	December 2019
Laser‐Induced Keyhole Defect Dynamics during Metal Additive Manufacturing Kiss, Andrew M.; Fong, Anthony Y.; Calta, Nicholas P. Advanced Engineering Materials, Vol. 21, Issue 10 https://doi.org/10.1002/adem.201970031	journal	October 2019
Statistical approach for assessing the effect of powder reuse on the final quality of AlSi10Mg parts produced by laser powder bed fusion additive manufacturing Del Re, F.; Contaldi, V.; Astarita, A. The International Journal of Advanced Manufacturing Technology, Vol. 97, Issue 5-8 https://doi.org/10.1007/s00170-018-2090-y	journal	May 2018
Effect of Build Orientation on Mechanical Properties and Microstructure of Ti-6Al-4V Manufactured by Selective Laser Melting Ren, Shubin; Chen, Yuhong; Liu, Tingting Metallurgical and Materials Transactions A, Vol. 50, Issue 9 https://doi.org/10.1007/s11661-019-05322-w	journal	June 2019
Overview on Microstructure- and Defect-Sensitive Fatigue Modeling of Additively Manufactured Materials Torries, Brian; Imandoust, Aidin; Beretta, Stefano JOM, Vol. 70, Issue 9 https://doi.org/10.1007/s11837-018-2987-9	journal	July 2018
Critical Features in the Microstructural Analysis of AISI 316L Produced By Metal Additive Manufacturing Saboori, Abdollah; Toushekhah, Mostafa; Aversa, Alberta Metallography, Microstructure, and Analysis, Vol. 9, Issue 1 https://doi.org/10.1007/s13632-019-00604-6	journal	January 2020
Pore elimination mechanisms during 3D printing of metals Hojjatzadeh, S. Mohammad H.; Parab, Niranjan D.; Yan, Wentao Nature Communications, Vol. 10, Issue 1 https://doi.org/10.1038/s41467-019-10973-9	journal	July 2019
An instrument for in situ time-resolved X-ray imaging and diffraction of laser powder bed fusion additive manufacturing processes Calta, Nicholas P.; Wang, Jenny; Kiss, Andrew M. Review of Scientific Instruments, Vol. 89, Issue 5 https://doi.org/10.1063/1.5017236	journal	May 2018
Sensor-Based Build Condition Monitoring in Laser Powder Bed Fusion Additive Manufacturing Process Using a Spectral Graph Theoretic Approach Montazeri, Mohammad; Rao, Prahalada Journal of Manufacturing Science and Engineering, Vol. 140, Issue 9 https://doi.org/10.1115/1.4040264	journal	June 2018
Additive manufacturing of CuCr1Zr by development of a gas atomization and laser powder bed fusion routine Jahns, Katrin; Bappert, Robin; Böhlke, Peter RWTH Aachen University https://doi.org/10.18154/rwth-2020-04017	text	January 2020
Effect of Surface and Subsurface Defects on Fatigue Behavior of AlSi10Mg Alloy Processed by Laser Powder Bed Fusion (L-PBF) Hamidi Nasab, Milad; Giussani, Alessandro; Gastaldi, Dario Metals, Vol. 9, Issue 10 https://doi.org/10.3390/met9101063	journal	September 2019
Inferring 3D ellipsoids based on cross-sectional images with applications to porosity control of additive manufacturing Wu, Jianguo; Yuan, Yuan; Gong, Haijun Taylor & Francis https://doi.org/10.6084/m9.figshare.5736816.v2	text	January 2018
Printability of 316 stainless steel Mukherjee, T.; DebRoy, T. Taylor & Francis https://doi.org/10.6084/m9.figshare.8015486.v1	text	January 2019
Data analytics approach for melt-pool geometries in metal additive manufacturing Lee, Seulbi; Peng, Jian; Shin, Dongwon Taylor & Francis https://doi.org/10.6084/m9.figshare.9988349	text	January 2019
Thermocapillary instabilities in a horizontal liquid layer under partial basal slip Kowal, Katarzyna; Davis, Sh; Voorhees, Pw Apollo - University of Cambridge Repository https://doi.org/10.17863/cam.39346	text	January 2018
Optimal Design for Metal Additive Manufacturing: An Integrated Computational Materials Engineering (ICME) Approach Motaman, S. Amir H.; Kies, Fabian Martin; Köhnen, Patrick RWTH Aachen University https://doi.org/10.18154/rwth-2020-02094	text	January 2020
Surface deformations in dynamic thermocapillary convection under partial slip. Kowal, Katarzyna; Davis, Stephen H.; Voorhees, Peter W. Apollo - University of Cambridge Repository https://doi.org/10.17863/cam.45334	text	January 2019
Inferring 3D ellipsoids based on cross-sectional images with applications to porosity control of additive manufacturing Wu, Jianguo; Yuan, Yuan; Gong, Haijun Taylor & Francis https://doi.org/10.6084/m9.figshare.5736816	text	January 2018
Additive manufacturing of CuCr1Zr by development of a gas atomization and laser powder bed fusion routine Jahns, Katrin; Bappert, Robin; Böhlke, Peter The International Journal of Advanced Manufacturing Technology, Vol. 107, Issue 5-6 https://doi.org/10.1007/s00170-020-04941-7	journal	March 2020
Data analytics approach for melt-pool geometries in metal additive manufacturing Lee, Seulbi; Peng, Jian; Shin, Dongwon Taylor & Francis https://doi.org/10.6084/m9.figshare.9988349.v1	text	January 2019
Ultrafast X-ray imaging of laser–metal additive manufacturing processes Parab, Niranjan D.; Zhao, Cang; Cunningham, Ross International Union of Crystallography (IUCr) https://doi.org/10.1107/s1600577518009554/mo5183sup1.avi	text	January 2018
Development of Bulk Metallic Glass Matrix Composites (BMGMC) by Additive Manufacturing: Modelling and Simulation – A Review: Part B Rafique, Muhammad Musaddique Ali; Niezgoda, Stephen; Brandt, Milan Advanced Materials Research, Vol. 1154 https://doi.org/10.4028/www.scientific.net/amr.1154.40	journal	June 2019
Single-Track Melt-Pool Measurements and Microstructures in Inconel 625 Ghosh, Supriyo; Ma, Li; Levine, Lyle E. arXiv https://doi.org/10.48550/arxiv.1802.05827	text	January 2018
Uncertainty Analysis of Microsegregation during Laser Powder Bed Fusion Ghosh, Supriyo; Mahmoudi, Mohamad; Johnson, Luke arXiv https://doi.org/10.48550/arxiv.1902.06785	text	January 2019
Application of finite element, phase-field, and CALPHAD-based methods to additive manufacturing of Ni-based superalloys Keller, Trevor; Lindwall, Greta; Ghosh, Supriyo Acta Materialia, Vol. 139 https://doi.org/10.1016/j.actamat.2017.05.003	journal	October 2017
Interpretation of the fatigue anisotropy of additively manufactured TA6V alloys via a fracture mechanics approach Le, Viet-Duc; Pessard, Etienne; Morel, Franck Engineering Fracture Mechanics, Vol. 214 https://doi.org/10.1016/j.engfracmech.2019.03.048	journal	June 2019
Post-heat treatment design for high-strength low-alloy steels processed by laser powder bed fusion Sridar, Soumya; Zhao, Yunhao; Li, Kun Materials Science and Engineering: A, Vol. 788 https://doi.org/10.1016/j.msea.2020.139531	journal	June 2020
Modeling of Processing-Induced Pore Morphology in an Additively-Manufactured Ti-6Al-4V Alloy Kabir, Mohammad; Richter, Henning Materials, Vol. 10, Issue 2 https://doi.org/10.3390/ma10020145	journal	February 2017
Effect of Hatch Spacing on Melt Pool and As-built Quality During Selective Laser Melting of Stainless Steel: Modeling and Experimental Approaches Dong, Zhichao; Liu, Yabo; Wen, Weibin Materials, Vol. 12, Issue 1 https://doi.org/10.3390/ma12010050	journal	December 2018
Impacts of Defocusing Amount and Molten Pool Boundaries on Mechanical Properties and Microstructure of Selective Laser Melted AlSi10Mg Zhou, Suyuan; Su, Yang; Gu, Rui Materials, Vol. 12, Issue 1 https://doi.org/10.3390/ma12010073	journal	December 2018
Study on the Numerical Simulation of the SLM Molten Pool Dynamic Behavior of a Nickel-Based Superalloy on the Workpiece Scale Cao, Liu; Yuan, Xuefeng Materials, Vol. 12, Issue 14 https://doi.org/10.3390/ma12142272	journal	July 2019
Process-Structure-Property Relationships of AISI H13 Tool Steel Processed with Selective Laser Melting Narvan, Morteza; Al-Rubaie, Kassim S.; Elbestawi, Mohamed Materials, Vol. 12, Issue 14 https://doi.org/10.3390/ma12142284	journal	July 2019
Stability of a Melt Pool during 3D-Printing of an Unsupported Steel Component and Its Influence on Roughness Skalon, Mateusz; Meier, Benjamin; Gruberbauer, Andreas Materials, Vol. 13, Issue 3 https://doi.org/10.3390/ma13030808	journal	February 2020
Single Tracks as a Key Factor in Additive Manufacturing Technology—Analysis of Research Trends and Metal Deposition Behavior Patalas-Maliszewska, Justyna; Feldshtein, Eugene; Devojno, Oleg Materials, Vol. 13, Issue 5 https://doi.org/10.3390/ma13051115	journal	March 2020
Simulation of non-Newtonian viscoplastic flows with a unified first order hyperbolic model and a structure-preserving semi-implicit scheme Peshkov, Ilya; Dumbser, Michael; Boscheri, Walter arXiv https://doi.org/10.48550/arxiv.2012.07656	text	January 2020

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