Transient Dynamics of Powder Spattering in Laser Powder Bed Fusion Additive Manufacturing Process Revealed by In-Situ High-Speed High-Energy X-Ray Imaging
Abstract
Powder spattering is a major cause of defect formation and quality uncertainty in the laser powder bed fusion (LPBF) additive manufacturing (AM) process. It is very difficult to investigate this with either conventional characterization tools or modeling and simulation. The detailed dynamics of powder spattering in the LPBF process is still not fully understood. Here, we report insights into the transient dynamics of powder spattering in the LPBF process that was observed with in-situ high-speed high-energy x-ray imaging. Powder motion dynamics, as a function of time, environment pressure, and location, is presented. The moving speed, acceleration, and driving force of powder motion that are induced by metal vapor jet/plume and argon gas flow are quantified. A schematic map showing the dynamics and mechanisms of powder motion during the LPBF process as functions of time and pressure is constructed. Potential ways to mitigate powder spattering during the LPBF process are discussed and proposed, based on the revealed powder motion dynamics and mechanisms.
Recommended Citation
Q. Guo and C. Zhao and L. I. Escano and Z. Young and L. Xiong and K. Fezzaa and W. Everhart and B. Brown and T. Sun and L. Chen, "Transient Dynamics of Powder Spattering in Laser Powder Bed Fusion Additive Manufacturing Process Revealed by In-Situ High-Speed High-Energy X-Ray Imaging," Acta Materialia, vol. 151, pp. 169 - 180, Elsevier, Jun 2018.
The definitive version is available at https://doi.org/10.1016/j.actamat.2018.03.036
Department(s)
Mechanical and Aerospace Engineering
Research Center/Lab(s)
Intelligent Systems Center
Keywords and Phrases
3D printers; Flow of gases; Image processing; X ray analysis; Additive manufacturing process; Characterization tools; Environment pressure; High speed imaging; Model and simulation; Powder bed; Spatter; Synchrotron x rays; Powder metals; Additive manufacturing; High-speed imaging; Powder bed fusion; Synchrotron x-ray
International Standard Serial Number (ISSN)
1359-6454
Document Type
Article - Journal
Document Version
Citation
File Type
text
Language(s)
English
Rights
© 2018 Elsevier, All rights reserved.
Publication Date
01 Jun 2018
Comments
This work is funded by Honeywell Federal Manufacturing & Technologies (FM & T), University of Missouri Research Board (UMRB), Intelligent Systems Center at Missouri S & T, National Science Foundation, and Laboratory Directed Research and Development (LDRD) funding from Argonne National Laboratory, provided by the Director, Office of Science, of the U.S. Department of Energy under Contract No. DE-AC02-06CH11357. This research used resources of the Advanced Photon Source, a U.S. Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02-06CH11357. This publication has been authored by Honeywell Federal Manufacturing & Technologies under Contract No. DE- NA0002839 with the U.S. Department of Energy.