Abstract
Expanding on prior process mapping work by the authors, multiple melt pool cross-sections are measured at multiple process parameter combinations for the Inconel 718 alloy in a Laser Powder Bed Fusion (L-PBF) process. Collection of such data enables the study of the variability of melt pool geometry (e.g. width, depth, and cross-sectional area) across process space. Furthermore, the statistical distribution of the measured melt pool geometries is compared to that of an equivalent normal distribution and intriguing outliers are observed. The cross-sectional morphology of the melt pools are associated with defects such as keyholing porosity and balling and the variability of the defects is quantified. The final product of this work is a robust description of L-PBF In718 melt pool behavior, based on ex-situ observations, which can be linked to in-situ observations of melt pool morphology in future work.
| Original language | English |
|---|---|
| Article number | 100830 |
| Journal | Additive Manufacturing |
| Volume | 29 |
| DOIs | |
| State | Published - Oct 2019 |
| Externally published | Yes |
Funding
This work was funded by Carnegie Mellon University's Manufacturing Futures Initiative under grant number 062900.005.105.100020.01. It would not be appropriate for anyone directly affiliated with either CMU's Mechanical Engineering or Materials Science and Engineering Departments in the last 5 years to review this work. As the lead author now works at Oak Ridge National Laboratory, it would also be inappropriate for anyone currently affiliated with ORNL's Manufacturing Demonstration Facility to review this work. There are no other known conflicts of interest to disclose. The authors would like to thank Dr. Sneha Prabha Narra (CMU) and Dr. Colt Montgomery (CMU) for their advice on polishing and etching In718, Dr. Brian Fisher (CMU) for their advice on experiment design, and Prof. Anthony Rollett (CMU) for their insight into appropriate statistical metrics. Funding for this work was provided by CMU's Manufacturing Futures Initiative (internal grant number 062900.005.105.100020.01). This work was funded by Carnegie Mellon University’s Manufacturing Futures Initiative under grant number 062900.005.105.100020.01 . It would not be appropriate for anyone directly affiliated with either CMU’s Mechanical Engineering or Materials Science and Engineering Departments in the last 5 years to review this work. As the lead author now works at Oak Ridge National Laboratory, it would also be inappropriate for anyone currently affiliated with ORNL’s Manufacturing Demonstration Facility to review this work. There are no other known conflicts of interest to disclose. The authors would like to thank Dr. Sneha Prabha Narra (CMU) and Dr. Colt Montgomery (CMU) for their advice on polishing and etching In718, Dr. Brian Fisher (CMU) for their advice on experiment design, and Prof. Anthony Rollett (CMU) for their insight into appropriate statistical metrics. Funding for this work was provided by CMU’s Manufacturing Futures Initiative (internal grant number 062900.005.105.100020.01).
Keywords
- Additive manufacturing
- Inconel 718
- Melt pool morphology
- Melt pool variability
- Statistical behavior