Spot Pattern Welding Scanning Strategy for Sensor Embedding and Residual Stress Reduction in Laser-Foil-Printing Additive Manufacturing

Abstract

Purpose: This paper aims to present spot pattern welding (SPW) as a scanning strategy for laser-foil-printing (LFP) additive manufacturing (AM) in place of the previously used continuous pattern welding (CPW) (line-raster scanning). The SPW strategy involves generating a sequence of overlapping spot welds on the metal foil, allowing the laser to form dense and uniform weld beads. This in turn reduces thermal gradients, promotes material consolidation and helps mitigate process-related risks such as thermal cracking, porosity, keyholing and Marangoni effects. Design/methodology/approach: 304L stainless steel (SS) feedstock is used to fabricate test specimens using the LFP system. Imaging techniques are used to examine the melt pool dimensions and layer bonding. In addition, the parts are evaluated for residual stresses, mechanical strength and grain size. Findings: Compared to CPW, SPW provides a more reliable heating/cooling relationship that is less dependent on part geometry. The overlapping spot welds distribute heat more evenly, minimizing the risk of elevated temperatures during the AM process. In addition, the resulting dense and uniform weld beads contribute to lower residual stresses in the printed part. Originality/value: To the best of the authors' knowledge, this is the first study to thoroughly investigate SPW as a scanning strategy using the LFP process. In general, SPW presents a promising strategy for securing embedded sensors into LFP parts while minimizing residual stresses.

Department(s)

Mechanical and Aerospace Engineering

Comments

Los Alamos National Laboratory, Grant 89233218CNA000001

Keywords and Phrases

Laser foil printing; Laser processing; Laser spot welding; Mechanical properties; Metal additive manufacturing; Residual stresses

International Standard Serial Number (ISSN)

1355-2546

Document Type

Article - Journal

Document Version

Citation

File Type

text

Language(s)

English

Rights

© 2024 Emerald, All rights reserved.

Publication Date

01 Jan 2024

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