Welding Metallurgy of

3D printing of Aluminium alloys: Additive Manufacturing of Aluminium alloys using selective laser melting

The laser–matter interaction and solidification phenomena associated with laser additive manufacturing (LAM) remain unclear, slowing its process development and optimisation. Here, through in situ and operando high-speed synchrotron X-ray imaging, we reveal the underlying physical phenomena during the deposition of the first and second layer melt tracks. We show that the laser-induced gas/vapour jet promotes the formation of melt tracks and denuded zones via spattering (at a velocity of 1 m s−1). We also uncover mechanisms of pore migration by Marangoni-driven flow (recirculating at a velocity of 0.4 m s−1), pore dissolution and dispersion by laser re-melting. We develop a mechanism map for predicting the evolution of melt features, changes in melt track morphology from a continuous hemi-cylindrical track to disconnected beads with decreasing linear energy density and improved molten pool wetting with increasing laser power. Our results clarify aspects of the physics behind LAM, which are critical for its development. Additive manufacturing of metals is now widely available, but the interaction of the metal powder with the laser remains unclear. Here, the authors use X-rays to image melt features and pore behaviour during laser melting of powders.

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In situ X-ray imaging of defect and molten pool dynamics in laser additive manufacturing

Laser powder bed fusion additive manufacturing is an emerging 3D printing technique for the fabrication of advanced metal components. Widespread adoption of it and similar additive technologies is hampered by poor understanding of laser-metal interactions under such extreme thermal regimes. Here, we elucidate the mechanism of pore formation and liquid-solid interface dynamics during typical laser powder bed fusion conditions using in situ X-ray imaging and multi-physics simulations. Pores are revealed to form during changes in laser scan velocity due to the rapid formation then collapse of deep keyhole depressions in the surface which traps inert shielding gas in the solidifying metal. We develop a universal mitigation strategy which eliminates this pore formation process and improves the geometric quality of melt tracks. Our results provide insight into the physics of laser-metal interaction and demonstrate the potential for science-based approaches to improve confidence in components produced by laser powder bed fusion. Laser-matter interactions during laser powder bed fusion additive manufacturing remain poorly understood. Here, the authors combine in situ X-ray imaging and finite element simulations to show how detrimental pores form under printing conditions and develop a strategy to suppress them.

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Dynamics of pore formation during laser powder bed fusion additive manufacturing.

Fluid and particle dynamics in laser powder bed fusion

High-speed imaging and schlieren imaging were used to investigate the interaction of the laser beam with the powder bed at pressures up to 5 bar, in argon and helium atmospheres. The entrainment of powder particles in the flow of shielding gas generated by the laser plume, and hence denudation, was reduced at high pressure for both gases. However, for argon, high pressure increased the temperature of both the melt pool and the laser plume, which significantly increased the generation of spatter and ionisation of the metal vapour with degraded surface smoothness and continuity. For helium, the formation of spatter and plasma did not increase with the increase in pressure above that observed at atmospheric pressure: its higher thermal conductivity and thermal diffusivity limited the laser plume temperature. Layers built at 5 bar in helium had a surface smoothness and continuity comparable to those built in argon at atmospheric pressure, but achieved at a higher laser scan speed, suggesting that a high-pressure helium atmosphere may be used to enhance the build rate.

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Laser powder bed fusion in high-pressure atmospheres

The perceived advantages of laser powder bed fusion (PBF) at reduced pressure include a more stable melt pool and reduced porosity. In this study, high-speed imaging was used to investigate the interaction of the laser beam with the powder bed at sub-atmospheric pressures. At atmospheric pressure, the laser plume produces a flow in the ambient atmosphere that entrains particles toward the melt pool. As the pressure decreases, this hydrodynamic entrainment increases but eventually the expansion of the laser plume prevents the particles reaching the melt pool: profiles and cross-sections of the track reveal a drastic reduction in its cross-sectional area. As the pressure decreases further, into the molecular flow regime, particles are only repelled by the plume away from the melt pool. The regime between 1 bar and ∼50 mbar (the threshold pressure at which the penetration depth no longer increases) could provide a window for successful processing but might require a pre-sinter to maintain the integrity of the powder bed. Lower pressures would definitely require a pre-sinter, for which the additional processing time and increase in process complexity might be justified for porosity-critical applications.

https://research.birmingham.ac.uk/portal/files/48786309/1_s2.0_S0890695518300671_main.pdf

Laser powder bed fusion at sub-atmospheric pressures

https://pure.hw.ac.uk/ws/files/16268784/1_s2.0_S092401361730568X_main.pdf

Visualisation and optimisation of shielding gas coverage during gas metal arc welding

https://pure.hw.ac.uk/ws/files/9635057/Download_pdf.pdf

Ioannis Bitharas

Papers

Fluid and particle dynamics in laser powder bed fusion

Laser powder bed fusion in high-pressure atmospheres

Laser powder bed fusion at sub-atmospheric pressures

Visualisation and optimisation of shielding gas coverage during gas metal arc welding

Visualisation of alternating shielding gas flow in GTAW