scholarly journals The use of non-spherical powder particles in Laser Powder Bed Fusion

2021 ◽  
Vol 1135 (1) ◽  
pp. 012018
Author(s):  
Tatiana Fedina ◽  
Jesper Sundqvist ◽  
Alexander F. H. Kaplan
Keyword(s):  
High Speed ◽  
Process Zone ◽  
Analytical Calculation ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
High Speed Imaging ◽  
Powder Morphology ◽  
Spherical Powder ◽  
Powder Bed ◽  
Computed Microtomography

Abstract Laser powder bed fusion (LPBF) generally involves the use of near-spherical powders due to their smooth morphology and enhanced flowability that allow for easier powder layering and laser processing. Non-spherical powders, on the other hand, are more cost-efficient to manufacture, however, the underlying mechanisms of their movement and interparticle interaction on the powder bed are still unclear. Thus, this study reports on the use of irregular iron-based powder material in LPBF, with a specific focus on particle motion and interaction behavior on the powder bed. The powder morphology, sphericity and particle size were analysed using X-ray computed microtomography and scanning electron microscopy. Based on the acquired data and by using a simplified analytical calculation, the influence of the particle shape/size on the particle movement in LPBF was established. High-speed imaging was employed to investigate the particle flow dynamics in the process zone, as well as the powder entrainment phenomenon. Particle entrainment and entrainment distances along the scanning direction were measured for near-spherical and non-spherical powders. The obtained results were compared between the powders, revealing a dissimilar particle transfer behavior. Non-spherical powder had a shorter entrainment distance partly attributed to the weaker drag force acting on these particles.

Measurement of the Melt Pool Length During Single Scan Tracks in a Commercial Laser Powder Bed Fusion Process

2017 ◽  
Author(s):  
J. C. Heigel ◽  
B. M. Lane
Keyword(s):  
Laser Power ◽  
High Speed ◽  
Infrared Camera ◽  
Powder Bed Fusion ◽  
Single Track ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Melt Pool ◽  
Significant Difference ◽  
Scan Speed

This work presents high speed thermographic measurements of the melt pool length during single track laser scans on nickel alloy 625 substrates. Scans are made using a commercial laser powder bed fusion machine while measurements of the radiation from the surface are made using a high speed (1800 frames per second) infrared camera. The melt pool length measurement is based on the detection of the liquidus-solidus transition that is evident in the temperature profile. Seven different combinations of programmed laser power (49 W to 195 W) and scan speed (200 mm/s to 800 mm/s) are investigated and numerous replications using a variety of scan lengths (4 mm to 12 mm) are performed. Results show that the melt pool length reaches steady state within 2 mm of the start of each scan. Melt pool length increases with laser power, but its relationship with scan speed is less obvious because there is no significant difference between cases performed at the highest laser power of 195 W. Although keyholing appears to affect the anticipated trends in melt pool length, further research is required.

scholarly journals In Situ Analysis of Laser Powder Bed Fusion Using Simultaneous High-Speed Infrared and X-ray Imaging

JOM ◽  
2020 ◽  
Vol 73 (1) ◽  
pp. 201-211 ◽  
Author(s):  
Benjamin Gould ◽  
Sarah Wolff ◽  
Niranjan Parab ◽  
Cang Zhao ◽  
Maria Cinta Lorenzo-Martin ◽  
...  
Keyword(s):  
High Speed ◽  
In Situ Analysis ◽  
Powder Bed Fusion ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
X Ray ◽  
X Ray Imaging

scholarly journals In-situ characterization of laser-powder interaction and cooling rates through high-speed imaging of powder bed fusion additive manufacturing

2017 ◽  
Vol 135 ◽  
pp. 385-396 ◽  
Author(s):  
Umberto Scipioni Bertoli ◽  
Gabe Guss ◽  
Sheldon Wu ◽  
Manyalibo J. Matthews ◽  
Julie M. Schoenung
Keyword(s):  
Additive Manufacturing ◽  
High Speed ◽  
Powder Bed Fusion ◽  
In Situ Characterization ◽  
High Speed Imaging ◽  
Cooling Rates ◽  
Powder Bed

scholarly journals In Situ Thermography During Laser Powder Bed Fusion of a Nickel Superalloy 625 Artifact with Various Overhangs and Supports

2021 ◽  
Vol 126 ◽  
Author(s):  
Benjamin Molnar ◽  
Jarred C. Heigel ◽  
Eric Whitenton
Keyword(s):  
Cooling Rate ◽  
High Speed ◽  
Nickel Superalloy ◽  
Powder Bed Fusion ◽  
Support Structures ◽  
Radiance Temperature ◽  
Laser Powder Bed Fusion ◽  
Powder Bed ◽  
Melt Pool

This document provides details on the experiment and associated measurement files available fordownload in the dataset “In Situ Thermography During Laser Powder Bed Fusion of a Nickel Superalloy 625 Artifact with Various Overhangs and Supports.” The measurements were acquired during the fabrication of a small nickel superalloy 625 (IN625) artifact using a commercial laser powder bed fusion (LPBF) system. The artifact consists of two half-arch features with increasing slopes for overhangs. These overhangs range from 5° from vertical to 85° from vertical in increments of 10°. The artifact geometry and process are controlled to ensure consistent processing along the overhang geometry. This control enables the effect of overhang geometry and support structures to be isolated from effects of inter-layer scan strategy variations. The measurements include high-speed thermography of each layer, from which radiance temperature, cooling rate, and melt pool length are calculated.

On Characterizing Uncertainty Sources in Laser Powder Bed Fusion Additive Manufacturing Models

2021 ◽  
Author(s):  
Tesfaye Moges ◽  
Kevontrez Jones ◽  
Shaw Feng ◽  
Paul Witherell ◽  
Gaurav Ameta
Keyword(s):  
Additive Manufacturing ◽  
Computational Models ◽  
Predictive Accuracy ◽  
Powder Bed Fusion ◽  
Metal Powders ◽  
Laser Powder Bed Fusion ◽  
Powder Morphology ◽  
Powder Bed ◽  
Uncertainty Sources ◽  
Ontology Language

Abstract Tremendous efforts have been made to use computational models of, and simulation models of, Additive Manufacturing (AM) processes. The goals of these efforts are to better understand process complexities and to realize better, high-quality parts. However, understanding whether any model is a correct representation for a given scenario is a difficult proposition. For example, when using metal powders, the laser powder bed fusion (L-PBF) process involves complex physical phenomena such as powder morphology, heat transfer, phase transformation, and fluid flow. Models based on these phenomena will possess different degrees of fidelity since they often rely on assumptions that may neglect or simplify process physics, resulting in uncertainties in their prediction accuracy. Predictive accuracy and its characterization can vary greatly between models due to their uncertainties. This paper characterizes several sources of L-PBF model uncertainty for low, medium, and high-fidelity thermal models including modeling assumptions (model-form uncertainty), numerical approximations (numerical uncertainty), and input parameters (parameter uncertainty). This paper focuses on the input uncertainty sources, which we model in terms of a probability density function (PDF), and its propagation through all other L-PBF models. We represent uncertainty sources using the Web Ontology Language (OWL), which allows us to capture the relevant knowledge used for interoperability and reusability. The topology and mapping of the uncertainty sources establish fundamental requirements for measuring model fidelity and for guiding the selection of a model suitable for its intended purpose.

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