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.; Martin, Aiden A.; Depond, Philip J.; Guss, Gabriel M.; Thampy, Vivek; Fong, Anthony Y.; Weker, Johanna Nelson; Stone, Kevin H.; Tassone, Christopher J.; Kramer, Matthew J.; Toney, Michael F.; Van Buuren, Anthony; Matthews, Manyalibo J.

doi:10.1063/1.5017236

Title: An instrument for in situ time-resolved X-ray imaging and diffraction of laser powder bed fusion additive manufacturing processes

Journal Article · Tue May 01 00:00:00 EDT 2018 · Review of Scientific Instruments

DOI:https://doi.org/10.1063/1.5017236· OSTI ID:1438740

Calta, Nicholas P. ^[1]; Wang, Jenny ^[1]; Kiss, Andrew M. ^[2];

^[1]; Depond, Philip J. ^[1]; Guss, Gabriel M. ^[1]; Thampy, Vivek ^[2]; Fong, Anthony Y. ^[2];

^[2];

^[2]; Tassone, Christopher J. ^[2];

^[3];

^[2]; Van Buuren, Anthony ^[1]; Matthews, Manyalibo J. ^[1]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
SLAC National Accelerator Lab., Menlo Park, CA (United States)
Iowa State Univ., Ames, IA (United States)

In situ X-ray-based measurements of the laser powder bed fusion (LPBF) additive manufacturing process produce unique data for model validation and improved process understanding. Synchrotron X-ray imaging and diffraction provide high resolution, bulk sensitive information with sufficient sampling rates to probe melt pool dynamics as well as phase and microstructure evolution. Here, we describe a laboratory-scale LPBF test bed designed to accommodate diffraction and imaging experiments at a synchrotron X-ray source during LPBF operation. We also present experimental results using Ti-6Al-4V, a widely used aerospace alloy, as a model system. Both imaging and diffraction experiments were carried out at the Stanford Synchrotron Radiation Lightsource. Melt pool dynamics were imaged at frame rates up to 4 kHz with a ~1.1 μm effective pixel size and revealed the formation of keyhole pores along the melt track due to vapor recoil forces. Diffraction experiments at sampling rates of 1 kHz captured phase evolution and lattice contraction during the rapid cooling present in LPBF within a ~50 × 100 μm area. In conclusion, we also discuss the utility of these measurements for model validation and process improvement.

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

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC52-07NA27344; CPA 32035; CPA 32037; CPA 32038

OSTI ID:: 1438740

Alternate ID(s):: OSTI ID: 1435482

Report Number(s):: LLNL-JRNL-739736; TRN: US1900507

Journal Information:: Review of Scientific Instruments, Vol. 89, Issue 5; ISSN 0034-6748

Publisher:: American Institute of Physics (AIP)Copyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 99 works

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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.201900455	journal	August 2019
Probing Ultrafast Dynamics in Laser Powder Bed Fusion Using High-Speed X-Ray Imaging: A Review of Research at the Advanced Photon Source Sun, Tao JOM, Vol. 72, Issue 3 https://doi.org/10.1007/s11837-020-04015-9	journal	January 2020
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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
In-situ high-speed X-ray imaging of piezo-driven directed energy deposition additive manufacturing Wolff, Sarah J.; Wu, Hao; Parab, Niranjan Scientific Reports, Vol. 9, Issue 1 https://doi.org/10.1038/s41598-018-36678-5	journal	January 2019
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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
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
A laser powder bed fusion system for in situ x-ray diffraction with high-energy synchrotron radiation Uhlmann, Eckart; Krohmer, Erwin; Schmeiser, Felix Deutsches Elektronen-Synchrotron, DESY, Hamburg https://doi.org/10.3204/pubdb-2020-02554	text	January 2020

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