Types of spatter and their features and formation mechanisms in laser powder bed fusion additive manufacturing process
Zachary A. Young,Zachary A. Young,Qilin Guo,Niranjan D. Parab,Cang Zhao,Minglei Qu,Luis I. Escano,Kamel Fezzaa,Wes Everhart,Tao Sun,Lianyi Chen +10 more
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TLDR
In this article, the features and formation mechanisms of five unique types of spatter during the LPBF process were revealed by in-situ high-speed, high-energy x-ray imaging.Abstract:
Spatter causes defect formation, powder redistribution and contamination in laser powder bed fusion (LPBF) additive manufacturing process It is critical to distinguish different types of spatter and understand their features and formation mechanisms This work reveals the features and formation mechanisms of five unique types of spatter during the LPBF process by in-situ high-speed, high-energy x-ray imaging Spatters observed during LPBF testing are quantified by their speed, size, and direction Distinct quantifiable characteristics for each type of spatter are identified Effects of the laser power, scan speed, and ambient pressure on spatter formation and features are unraveled A spatter formation map for AlSi10Mg alloy is constructedread more
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Defects and anomalies in powder bed fusion metal additive manufacturing
Amir Mostafaei,Cang Zhao,Yining He,Seyed Reza Ghiaasiaan,Bo Shi,Shuai Shao,Nima Shamsaei,Ziheng Wu,Nadia Kouraytem,Tao Sun,Joseph Pauza,Jerard V. Gordon,Bryan A. Webler,Niranjan D. Parab,Mohammadreza Asherloo,Qi Chao Guo,Lianyi Chen,Anthony D. Rollett +17 more
TL;DR: In this article , a review of common defects and anomalies in powder bed fusion metal additive manufacturing processes is presented, where the formation mechanism and practical mitigation strategies are discussed, as well as properties such as mechanical behavior and corrosion resistance of defective parts.
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.
Journal ArticleDOI
Making sustainable aluminum by recycling scrap: The science of “dirty” alloys
Dierk Raabe,Dirk Ponge,Peter J. Uggowitzer,Moritz Roscher,Mario Paolantonio,Chuanlai Liu,Helmut Antrekowitsch,Ernst Kozeschnik,David Seidmann,Bat Gault,Frédéric De Geuser,Alexis Dechamps,Christopher Hutchinson,Chunhui Liu,Zhimin Liu,Philip B. Prangnell,Joseph D. Robson,Pratheek Shanthraj,Samad Vakili,Chad W. Sinclair,Laure Bourgeois,Stefan Pogatscher +21 more
TL;DR: In this paper , the influence of scrap-related impurities on the thermodynamics and kinetics of precipitation reactions and their mechanical and electrochemical effects; impurity effects on precipitation-free zones around grain boundaries; their effects on casting microstructures; and the possibilities presented by adjusting processing parameters and the associated mechanical, functional and chemical properties.
Journal ArticleDOI
Metal vaporization and its influence during laser powder bed fusion process
Jing Liu,Pengyu Wen +1 more
TL;DR: In this article , a comprehensive review of metal vaporization during laser powder bed fusion was conducted, in terms of its influence and underlying mechanism, as well as numerical simulations, and the vaporization loss of elements could be quantitatively adjusted to regulate the compositional distribution.
Journal ArticleDOI
In-situ monitoring and detection of spatter agglomeration and delamination during laser-based powder bed fusion of Invar 36
TL;DR: In this paper, an in-situ monitoring setup for detecting spatters and delamination of Invar 36 was presented, where the size, shape, count, and cooling rate of spatter particles were evaluated using a combination of infrared pyrometer and high-speed infrared thermography.
References
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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 additive manufacturing of metallic components: materials, processes and mechanisms
TL;DR: Additive manufacturing implies layer by layer shaping and consolidation of powder feedstock to arbitrary configurations, normally using a computer controlled laser as discussed by the authors, which is based on a novel materials incremental manufacturing philosophy.
Journal ArticleDOI
The status, challenges, and future of additive manufacturing in engineering
Wei Gao,Yunbo Zhang,Devarajan Ramanujan,Karthik Ramani,Yong Chen,Christopher B. Williams,Charlie C. L. Wang,Yung C. Shin,Song Zhang,Pablo D. Zavattieri +9 more
TL;DR: Future directions such as the "print-it-all" paradigm, that have the potential to re-imagine current research and spawn completely new avenues for exploration are pointed out.
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
Review of selective laser melting : materials and applications
Chor Yen Yap,Chee Kai Chua,Zhili Dong,Zhong Hong Liu,Dan Qing Zhang,Loong Ee Loh,Swee Leong Sing +6 more
TL;DR: Selective laser melting (SLM) is a particular rapid prototyping, 3D printing, or additive manufacturing (AM) technique designed to use high power-density laser to melt and fuse metallic powders as mentioned in this paper.