Melt pool geometry and morphology variability for the Inconel 718 alloy in a laser powder bed fusion additive manufacturing process

2019 ◽  
Vol 29 ◽  
pp. 100830 ◽  
Author(s):  
Luke Scime ◽  
Jack Beuth
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Inconel 718 ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Inconel 718 Alloy ◽  
Powder Bed ◽  
Melt Pool

scholarly journals Effects on the distortion of Inconel 718 components along a hybrid laser-based additive manufacturing process chain using laser powder bed fusion and laser metal deposition

2021 ◽  
Author(s):  
Eckart Uhlmann ◽  
Jan Düchting ◽  
Torsten Petrat ◽  
Erwin Krohmer ◽  
Benjamin Graf ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Inconel 718 ◽  
Powder Bed Fusion ◽  
Laser Metal Deposition ◽  
Process Chain ◽  
Laser Powder Bed Fusion ◽  
Plate Material ◽  
Powder Bed ◽  
Manufacturing Process Chain

AbstractThe combination of laser powder bed fusion (LPBF), known for its geometrical freedom and accuracy, and the nozzle-based laser metal deposition process (LMD), known for its high build-up rates, has great potential to reduce the additive manufacturing times for large metallic parts. For the industrial application of the LPBF-LMD hybrid process chain, it is necessary to investigate the influence of the LMD process on the LPBF substrate. In addition, the build plate material also has a significant impact on the occurrence of distortion along the additive manufacturing process chain. In the literature, steel build plates are often used in laser-based additive manufacturing processes of Inconel 718, since a good metallurgical bonding can be assured whilst reducing costs in the production and restoration of the build plates. This paper examines the distortion caused by LMD material deposition and the influence of the build plate material along the hybrid additive manufacturing process chain. Twin cantilevers are manufactured by LPBF and an additional layer is subsequently deposited with LMD. The distortion is measured in the as-built condition as well as after heat treatment. The effect of different LMD hatch strategies on the distortion is determined. The experiments are conducted using the nickel-base alloy Inconel 718. The results show a significant influence of LMD path strategies on distortion, with shorter tool paths leading to less distortion. The remaining distortion after heat treatment is considerably dependent on the material of the build plate.

scholarly journals A multi-scale multi-physics modeling framework of laser powder bed fusion additive manufacturing process

2018 ◽  
Vol 73 (3) ◽  
pp. 151-157 ◽  
Author(s):  
Jing Zhang ◽  
Yi Zhang ◽  
Weng Hoh Lee ◽  
Linmin Wu ◽  
Hyun-Hee Choi ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Modeling Framework ◽  
Powder Bed ◽  
Multi Scale ◽  
Physics Modeling

scholarly journals Types of spatter and their features and formation mechanisms in laser powder bed fusion additive manufacturing process

2020 ◽  
Vol 36 ◽  
pp. 101438
Author(s):  
Zachary A. Young ◽  
Qilin Guo ◽  
Niranjan D. Parab ◽  
Cang Zhao ◽  
Minglei Qu ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Formation Mechanisms ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed

Hybrid Modeling Approach for Melt Pool Prediction in Laser Powder Bed Fusion Additive Manufacturing

2020 ◽  
Author(s):  
Tesfaye Moges ◽  
Zhuo Yang ◽  
Kevontrez Jones ◽  
Shaw Feng ◽  
Paul Witherell ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Hybrid Model ◽  
Hybrid Models ◽  
Hybrid Modeling ◽  
Data Driven ◽  
Powder Bed Fusion ◽  
Cfd Model ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Melt Pool

Abstract Multi-scale, multi-physics, computational models are a promising tool to provide detailed insights to understand the process-structure-property-performance relationships in additive manufacturing (AM) processes. To take advantage of the strengths of both physics-based and data-driven models, we propose a novel, hybrid modeling framework for laser powder bed fusion (L-PBF) processes. Our unbiased, model integration method combines physics-based data and measurement data for approaching more accurate prediction of melt-pool width. Both a high-fidelity computational fluid dynamics (CFD) model and experiments utilizing optical images are used to generate a combined dataset of melt-pool widths. From this aggregated dataset, a hybrid model is developed using data-driven modeling techniques, including polynomial regression and Kriging methods. The performance of the hybrid model is evaluated by computing the average relative error and comparing it with the results of the simulations and surrogate models constructed from the original CFD model and experimental measurements. It is found that the proposed hybrid model performs better in terms of prediction accuracy and computational time. Future work includes a conceptual introduction on the use of an AM ontology to support improved model and data selection when constructing hybrid models. This study can be viewed as a significant step towards the use of hybrid models as predictive models with improved accuracy and without the sacrifice of speed.

scholarly journals Microstructure and Residual Stress Evolution of Laser Powder Bed Fused Inconel 718 under Heat Treatments

2020 ◽  
Author(s):  
Giulio Marchese ◽  
Eleonora Atzeni ◽  
Alessandro Salmi ◽  
Sara Biamino
Keyword(s):  
Residual Stresses ◽  
Inconel 718 ◽  
Heat Treatments ◽  
Powder Bed Fusion ◽  
Stress Evolution ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Melt Pool ◽  
Sintering Mechanisms ◽  
Dendritic Structures

AbstractThe current work aimed to study the influence of various heat treatments on the microstructure, hardness, and residual stresses of Inconel 718 processed by laser powder bed fusion process. The reduction in residual stresses is crucial to avoid the deformation of the component during its removal from the building platform. Among the different heat treatments, 800 °C kept almost unaltered the original microstructure, reducing the residual stresses. Heat treatments at 900, 980, and 1065 °C gradually triggered the melt pool and dendritic structures dissolution, drastically reducing the residual stresses. Heat treatments at 900 and 980 °C involved the formation of δ phases, whereas 1065 °C generated carbides. These heat treatments were also performed on components with narrow internal channels revealing that heat treatments up to 900 °C did not trigger sintering mechanisms allowing to remove the powder from the inner channels.

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