Melt Pool Analysis and Mesoscale Simulation of Laser Powder Bed Fusion Process (L-PBF) with Ti-6Al-4V Powder Particles

JOM ◽  
2018 ◽  
Vol 71 (3) ◽  
pp. 938-945 ◽  
Author(s):  
Santosh K. Rauniyar ◽  
Kevin Chou
Keyword(s):  
Pool Analysis ◽  
Fusion Process ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Mesoscale Simulation ◽  
Powder Bed ◽  
Melt Pool ◽  
Powder Particles

Transient Melt Pool Formation in Laser-Powder Bed Fusion Process

2020 ◽  
Author(s):  
Santosh Rauniyar ◽  
Kevin Chou
Keyword(s):  
Steady State ◽  
Transient State ◽  
Fusion Process ◽  
Quasi Steady State ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Melt Pool ◽  
Scan Speed ◽  
Powder Particles

Abstract Parts are built in a layer-by-layer fashion in the laser powder bed fusion process. Each layer of scan in the parts is defined by a scan strategy that consists of many small patches and scans. The scan length of those multiple scans is not always long enough to have reached a quasi-steady state of the melt pool. The length at which it achieves a steady state is different for different process parameters. The available literature related to the melt pool considers the melt pool has already achieved a steady state, which holds true to a large extent. However, there is always a transient state of melt pool with different characteristics compared to the quasi-steady state. The transient state of the melt pool is particularly significant for small features and thin walls. This paper explores the cross-section and width of the melt track in the transient state. Single-tracks are deposited on semi-cylindrical samples with Ti-6Al-4V powder particles for three levels of power and speed combinations. The single tracks are built at a certain height from the base plate instead of on the build plate to include the effect of the powder particles. The experiment includes single tracks of four scan lengths i.e. 0.25, 0.5, 1 and 2 mm. Once the parts are built and removed from the build plate, White light interferometer is used to capture the melt track information and data processing is done in Matlab™. The results show that the transient length is directly proportional to the laser power and inversely proportional to the scan speed. The highest transient length value is obtained for the highest power of 195 W and lowest scan speed of 50 mm/s.

Vision-based in-situ monitoring system for melt-pool detection in laser powder bed fusion process

2021 ◽  
Vol 68 ◽  
pp. 1735-1745
Author(s):  
Trong-Nhan Le ◽  
Min-Hsun Lee ◽  
Ze-Hong Lin ◽  
Hong-Chuong Tran ◽  
Yu-Lung Lo
Keyword(s):  
Monitoring System ◽  
In Situ Monitoring ◽  
Fusion Process ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Melt Pool

scholarly journals Vacuum laser powder bed fusion—track consolidation, powder denudation, and future potential

2020 ◽  
Vol 110 (11-12) ◽  
pp. 3339-3346
Author(s):  
L. Kaserer ◽  
S. Bergmueller ◽  
J. Braun ◽  
G. Leichtfried
Keyword(s):  
Laser Plasma ◽  
Powder Layer ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Laser Plasma Interaction ◽  
Melt Pool ◽  
Powder Particles ◽  
Future Potential ◽  
Titanium Grade

Abstract Defects in parts processed by laser powder bed fusion (LPBF) are often triggered by laser/plasma plume interference and spattering. The implementation of a LPBF process in vacuum has been suggested to possibly reduce these effects. Within this study, the effects of process pressure variations between 1 mbar and atmospheric pressure on the generation of single tracks and on the surrounding layer of loose powder particles were studied for CP titanium grade 2 and the Maraging steel 1.2709. Below 10 mbar no single tracks could be generated and the powder layer adjacent to the track was effectively denuded. It was found that the essential mechanism for incorporating powder into the melt pool begins to work at process pressures above 10 mbar and its effectiveness increases with increasing pressure. The amount of powder incorporated into the melt pool depends on the material and the scanning conditions. With identical scanning conditions, this amount of powder is significantly larger for titanium than for steel. For process pressures above 200 mbar, no significant change in the amount of spattering could be found. In this pressure range improved process stability could be possible due to a reduced laser/plasma interaction and an increased laser penetration depth.

scholarly journals Role of laser powder bed fusion process parameters in crystallographic texture of additive manufactured Nb-48Ti alloy

2021 ◽  
Author(s):  
Rafael de Moura Nobre ◽  
Willy Ank de Morais ◽  
Matheus Tavares Vasques ◽  
Jhoan Guzmán ◽  
Daniel Luiz Rodrigues Junior ◽  
...  
Keyword(s):  
Process Parameters ◽  
Crystallographic Texture ◽  
Fusion Process ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed

scholarly journals Optimization of Laser Powder Bed Fusion Processing Using a Combination of Melt Pool Modeling and Design of Experiment Approaches: Density Control

2019 ◽  
Vol 3 (1) ◽  
pp. 21 ◽  
Author(s):  
Morgan Letenneur ◽  
Alena Kreitcberg ◽  
Vladimir Brailovski
Keyword(s):  
Scanning Speed ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Density Prediction ◽  
Melt Pool ◽  
Density Control ◽  
Pool Model ◽  
Conventional Material ◽  
Prediction Approach

A simplified analytical model of the laser powder bed fusion (LPBF) process was used to develop a novel density prediction approach that can be adapted for any given powder feedstock and LPBF system. First, calibration coupons were built using IN625, Ti64 and Fe powders and a specific LPBF system. These coupons were manufactured using the predetermined ranges of laser power, scanning speed, hatching space, and layer thickness, and their densities were measured using conventional material characterization techniques. Next, a simplified melt pool model was used to calculate the melt pool dimensions for the selected sets of printing parameters. Both sets of data were then combined to predict the density of printed parts. This approach was additionally validated using the literature data on AlSi10Mg and 316L alloys, thus demonstrating that it can reliably be used to optimize the laser powder bed metal fusion process.

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