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

State-of-the-art metal 3D printers promise to revolutionize manufacturing, yet they have not reached optimal operational reliability. The challenge is to control complex laser-powder-melt pool interdependency (dependent upon each other) dynamics. We used high-fidelity simulations, coupled with synchrotron experiments, to capture fast multitransient dynamics at the meso-nanosecond scale and discovered new spatter-induced defect formation mechanisms that depend on the scan strategy and a competition between laser shadowing and expulsion. We derived criteria to stabilize the melt pool dynamics and minimize defects. This will help improve build reliability.

Controlling interdependent meso-nanosecond dynamics and defect generation in metal 3D printing

We report the design of a metal powder bed fusion system for in-situ monitoring of the build process during additive manufacture. Its open-architecture design was originally determined to enable access for x-rays to the melt pool, but it also provides access to the build area for a range of other in-situ measurement techniques. The system is sufficiently automated to enable single tracks and high-density, multiple layer components to be built. It is easily transportable to enable measurements at different measurement facilities and its modular design enables straightforward modification for the specific measurements being made. We demonstrate that the system produces components with >99% density. Hence the build conditions are representative to observe process fundamentals and to develop process control strategies.

https://pure.hw.ac.uk/ws/files/15577966/1_s2.0_S2214860416303700_main.pdf

An open-architecture metal powder bed fusion system for in-situ process measurements

Recent advances in additive manufacturing (AM) have attracted significant industrial interest. Initially, AM was mainly associated with the fabrication of prototypes, but the AM advances together with the broadening range of available materials, especially for producing metallic parts, have broaden the application areas and now the technology can be used for manufacturing functional parts, too. Especially, the AM technologies enable the creation of complex and topologically optimised geometries with internal cavities that were impossible to produce with traditional manufacturing processes. However, the tight geometrical tolerances along with the strict surface integrity requirements in aerospace, biomedical and automotive industries are not achievable in most cases with standalone AM technologies. Therefore, AM parts need extensive post-processing to ensure that their surface and dimensional requirements together with their respective mechanical properties are met. In this context, it is not surprising that the integration of AM with post-processing technologies into single and multi set-up processing solutions, commonly referred to as hybrid AM, has emerged as a very attractive proposition for industry while attracting a significant R&D interest. This paper reviews the current research and technology advances associated with the hybrid AM solutions. The special focus is on hybrid AM solutions that combine the capabilities of laser-based AM for processing powders with the necessary post-process technologies for producing metal parts with required accuracy, surface integrity and material properties. Commercially available hybrid AM systems that integrate laser-based AM with post-processing technologies are also reviewed together with their key application areas. Finally, the main challenges and open issues in broadening the industrial use of hybrid AM solutions are discussed.

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Powder-based laser hybrid additive manufacturing of metals: a review

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

Prveen Bidare

Papers

Fluid and particle dynamics in laser powder bed fusion

An open-architecture metal powder bed fusion system for in-situ process measurements

Powder-based laser hybrid additive manufacturing of metals: a review

Laser powder bed fusion in high-pressure atmospheres

Laser powder bed fusion at sub-atmospheric pressures