In-situ full-field mapping of melt flow dynamics in laser metal additive manufacturing
Qilin Guo,Qilin Guo,Cang Zhao,Minglei Qu,Minglei Qu,Lianghua Xiong,S. Mohammad H. Hojjatzadeh,S. Mohammad H. Hojjatzadeh,Luis I. Escano,Luis I. Escano,Niranjan D. Parab,Kamel Fezzaa,Tao Sun,Lianyi Chen,Lianyi Chen +14 more
Reads0
Chats0
TLDR
In this article, Zhao et al. reported in-situ characterization of melt-flow dynamics in every location of the entire melt pool in laser metal additive manufacturing by populous and uniformly dispersed micro-tracers through high-resolution synchrotron x-ray imaging.Abstract:
Melt flow plays a critical role in laser metal additive manufacturing, yet the melt flow behavior within the melt pool has never been explicitly presented. Here, we report in-situ characterization of melt-flow dynamics in every location of the entire melt pool in laser metal additive manufacturing by populous and uniformly dispersed micro-tracers through in-situ high-resolution synchrotron x-ray imaging. The location-specific flow patterns in different regions of the melt pool are revealed and quantified under both conduction-mode and depression-mode melting. The physical processes at different locations in the melt pool are identified. The full-field melt-flow mapping approach reported here opens the way to study the detailed melt-flow dynamics under real additive manufacturing conditions. The results obtained provide crucial insights into laser additive manufacturing processes and are critical for developing reliable high-fidelity computational models.read more
Citations
More filters
Journal ArticleDOI
Direct Observation of Pore Formation Mechanisms during LPBF Additive Manufacturing Process and High Energy Density Laser Welding
S. Mohammad H. Hojjatzadeh,S. Mohammad H. Hojjatzadeh,Niranjan D. Parab,Qilin Guo,Minglei Qu,Lianghua Xiong,Cang Zhao,Luis I. Escano,Luis I. Escano,Kamel Fezzaa,Wes Everhart,Tao Sun,Lianyi Chen,Lianyi Chen +13 more
TL;DR: In this article, the pore formation mechanism during the laser powder bed fusion (LPBF) process is investigated. And the results provide direct evidence and insight into pore forming mechanisms during the LPBF process, which may guide the development of pore elimination/mitigation approaches.
Journal ArticleDOI
Machine learning for metal additive manufacturing: predicting temperature and melt pool fluid dynamics using physics-informed neural networks
TL;DR: In this article, a physics-informed neural network (PINN) framework was proposed to predict the temperature and melt pool dynamics during metal additive manufacturing (AM) processes with only a moderate amount of labeled data sets.
Posted Content
Machine learning for metal additive manufacturing: Predicting temperature and melt pool fluid dynamics using physics-informed neural networks
TL;DR: The investigations show that the PINN, owed to the additional physical knowledge, can accurately predict the temperature and melt pool dynamics during metal AM processes with only a moderate amount of labeled data-sets.
Journal ArticleDOI
In situ design of advanced titanium alloy with concentration modulations by additive manufacturing.
Tianlong Zhang,Tianlong Zhang,Zhenghua Huang,Tao Yang,Haojie Kong,Junhua Luan,Anding Wang,Dong Wang,Way Kuo,Yunzhi Wang,C.T. Liu +10 more
TL;DR: Additive manufacturing is a revolutionary technology that offers a different pathway for material processing and design as mentioned in this paper, however, innovations in either new materials or new processing technologies have not yet materialized.
Journal ArticleDOI
In-situ measurement and monitoring methods for metal powder bed fusion: an updated review
TL;DR: In this paper, the authors present an updated review of the literature on in-situ sensing, measurement and monitoring for metal PBF processes, with a classification of methods and a comparison of enabled performances, summarising the types and sizes of defects that are practically detectable while the part is being produced and the research areas where additional technological advances are currently needed.
References
More filters
Journal ArticleDOI
Additive manufacturing of metallic components – Process, structure and properties
Tarasankar Debroy,Huiliang Wei,J.S. Zuback,T. Mukherjee,John W. Elmer,John O. Milewski,Allison M. Beese,Alexander E. Wilson-Heid,Amitava De,Wei Zhang +9 more
TL;DR: A review of the emerging research on additive manufacturing of metallic materials is provided in this article, which provides a comprehensive overview of the physical processes and the underlying science of metallurgical structure and properties of the deposited parts.
Journal ArticleDOI
Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones
TL;DR: In this paper, the effect of the recoil pressure and Marangoni convection in laser powder bed fusion (L-PBF) of 316L stainless steel was demonstrated. And the results were validated against the experiments and the sensitivity to laser absorptivity was discussed.
Journal ArticleDOI
Keyhole threshold and morphology in laser melting revealed by ultrahigh-speed x-ray imaging
Ross B. Cunningham,Cang Zhao,Niranjan D. Parab,Christopher Kantzos,Joseph Pauza,Kamel Fezzaa,Tao Sun,Anthony D. Rollett +7 more
TL;DR: The direct visualization of the keyhole morphology and dynamics with high-energy x-rays shows that (i) keyholes are present across the range of power and scanning velocity used in laser powder bed fusion; and (ii) there is a well-defined threshold from conduction mode to keyhole based on laser power density.
Journal ArticleDOI
Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction
Cang Zhao,Kamel Fezzaa,Ross B. Cunningham,Haidan Wen,Francesco De Carlo,Lianyi Chen,Anthony D. Rollett,Tao Sun +7 more
TL;DR: The high-speed synchrotron hard X-ray imaging and diffraction techniques used to monitor the laser powder bed fusion (LPBF) process of Ti-6Al-4V in situ and in real time demonstrate that many scientifically and technologically significant phenomena in LPBF, including melt pool dynamics, powder ejection, rapid solidification, and phase transformation, can be probed with unprecedented spatial and temporal resolutions.
Journal ArticleDOI
In situ X-ray imaging of defect and molten pool dynamics in laser additive manufacturing
Chu Lun Alex Leung,Sebastian Marussi,Robert Atwood,Michael Towrie,Philip J. Withers,Peter D. Lee +5 more
TL;DR: 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 is developed.