Role of scan strategies on thermal gradient and solidification rate in electron beam powder bed fusion

Lee, Yousub; Kirka, Michael M.; Dinwiddie, Ralph Barton; Raghavan, Narendran; Turner, John A.; Dehoff, Ryan R.; Babu, Sudarsanam Suresh

doi:10.1016/j.addma.2018.04.038

Title: Role of scan strategies on thermal gradient and solidification rate in electron beam powder bed fusion

Journal Article · Wed Aug 01 00:00:00 EDT 2018 · Additive Manufacturing

DOI:https://doi.org/10.1016/j.addma.2018.04.038· OSTI ID:1458379

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Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility; Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Materials Science & Technology Division
Univ. of Tennessee, Knoxville, TN (United States). Dept. of Mechanical, Aerospace and Biomedical Engineering; Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Computer Science and Mathematics Division
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Computer Science and Mathematics Division
Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States). Manufacturing Demonstration Facility; Univ. of Tennessee, Knoxville, TN (United States). Dept. of Mechanical, Aerospace and Biomedical Engineering

Local microstructure control in electron beam powder bed fusion (EB-PBF) is of great interest to the additive manufacturing community to realize complex part geometry with targeted performance. The local microstructure control relies on having a detailed understanding of local melt pool physics (e.g., 3-D melt pool shape as well as spatial and temporal variations of thermal gradient (G) and solidification rate (R)). In this research, a new scan strategy referred to as ghost beam is numerically evaluated as a candidate to achieve the targeted G and R of IN718 alloy. The boundary conditions for simulations, including the speed (490 mm/s) and spatial locations of the beam within a given layer, are obtained by using series of snapshot images, recorded at 12,000 frames per second, using a high-speed camera. The heat transfer simulations were performed using TRUCHAS an open-source software deployed within a high-performance computational infrastructure. The simulation results showed that reheating at short beam on-time and time delay decreases both G and R. Local variation of R at the center of the melt pool trailing edge showed periodic temporal fluctuations. Finally, the ghost beam scan strategy was compared to other existing raster and spot scan strategies.

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Research Organization:: Oak Ridge National Laboratory (ORNL), Oak Ridge, TN (United States)

Sponsoring Organization:: USDOE

Grant/Contract Number:: AC05-00OR22725

OSTI ID:: 1458379

Journal Information:: Additive Manufacturing, Vol. 22, Issue C; ISSN 2214-8604

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 43 works

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