Towards process consistency and in-situ evaluation of porosity during laser powder bed additive manufacturing

J. Raplee; J. Gockel; F. List; K. Carver; S. Foster; T. McFalls; V. Paquit; R. Rao; D. W. Gandy; S. S. Babu

doi:10.1080/13621718.2020.1823654

Towards process consistency and in-situ evaluation of porosity during laser powder bed additive manufacturing

J. Raplee, J. Gockel, F. List, K. Carver, S. Foster, T. McFalls, V. Paquit, R. Rao, D. W. Gandy, S. S. Babu

Research output: Contribution to journal › Article › peer-review

10 Scopus citations

Abstract

There is a synergy between welding and additive manufacturing with reference to spatial and temporal variations of heat transfer. In this research, in-situ measurements of heat transfer conditions are considered as a viable qualification methodology for additive manufacturing (AM). Infrared imaging (IR) was performed within a laser powder bed fusion (L-PBF) AM machine equipped with an IR camera. Infrared thermal signatures as a function of space and time, while processing Ti6Al4V and 316L stainless steel powders, were extracted and analysed. The analyses correlated the defect evolution at low- and high-heat input conditions to thermal decay and integrated intensities. The IR based results were validated by processing a 316L cylinder with engineered porosities and detecting the same with ground truth data from computed tomography.

Original language	English
Pages (from-to)	679-689
Number of pages	11
Journal	Science and Technology of Welding and Joining
Volume	25
Issue number	8
DOIs	https://doi.org/10.1080/13621718.2020.1823654
State	Published - Nov 16 2020

Funding

Authors acknowledge partial support from the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT- Battelle, LLC. Part of the research is also supported by the Office of Nuclear Energy, Nuclear Energy Enabling Technologies program under DE-NE0000544 contract with Electric Power Research Institute. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05- 00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, worldwide licence to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. JG’s contribution to this research was supported as part of the Higher Education Research Experience Faculty Program at Oak Ridge National Laboratory. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan ( http://energy.gov/downloads/doe-<https://protect-au.mi-mecast.com/s/_KwPCzvOWKi2XLEji4-GuE?domain=ene-rgy.gov ). Part of the research at UTK by Babu is sponsored by the US Department of the Navy, Office of Naval Research under ONR award number N00014-18-1-2794. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the Office of Naval Research. This work was supported by Multidisciplinary University Research Initiative [grant number N00014-18-1-2794]; Nuclear Energy Enabling Technologies [grant number DE-NE0000544]; Office of Energy Efficiency and Renewable Energy [grant number DE-AC05-00OR22725]. Authors acknowledge partial support from the U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT- Battelle, LLC. Part of the research is also supported by the Office of Nuclear Energy, Nuclear Energy Enabling Technologies program under DE-NE0000544 contract with Electric Power Research Institute. This manuscript has been authored by UT-Battelle, LLC under Contract No. DE-AC05- 00OR22725 with the U.S. Department of Energy. The United States Government retains and the publisher, by accepting the article for publication, acknowledges that the United States Government retains a non-exclusive, paid-up, irrevocable, worldwide licence to publish or reproduce the published form of this manuscript, or allow others to do so, for United States Government purposes. JG’s contribution to this research was supported as part of the Higher Education Research Experience Faculty Program at Oak Ridge National Laboratory. The Department of Energy will provide public access to these results of federally sponsored research in accordance with the DOE Public Access Plan (http://energy.gov/downloads/doe-<https://protect-au.mi-mecast.com/s/_KwPCzvOWKi2XLEji4-GuE?domain=ene-rgy.gov). Part of the research at UTK by Babu is sponsored by the US Department of the Navy, Office of Naval Research under ONR award number N00014-18-1-2794. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the Office of Naval Research.

Funders	Funder number
DOE Public Access Plan
Nuclear Energy Enabling Technologies
United States Government
Office of Naval Research	N00014-18-1-2794
U.S. Department of Energy
Advanced Manufacturing Office	DE-AC05-00OR22725
Office of Energy Efficiency and Renewable Energy
Office of Nuclear Energy	DE-NE0000544
Oak Ridge National Laboratory
Electric Power Research Institute	DE-AC05- 00OR22725
U.S. Navy
Multidisciplinary University Research Initiative

Keywords

Laser powder bed fusion
Ti6Al4V and 316L stainless steels
X-ray computed tomography defect formation
additive manufacturing
in-situ infrared measurements

UN SDGs

This output contributes to the following UN Sustainable Development Goals (SDGs)

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10.1080/13621718.2020.1823654

Cite this

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abstract = "There is a synergy between welding and additive manufacturing with reference to spatial and temporal variations of heat transfer. In this research, in-situ measurements of heat transfer conditions are considered as a viable qualification methodology for additive manufacturing (AM). Infrared imaging (IR) was performed within a laser powder bed fusion (L-PBF) AM machine equipped with an IR camera. Infrared thermal signatures as a function of space and time, while processing Ti6Al4V and 316L stainless steel powders, were extracted and analysed. The analyses correlated the defect evolution at low- and high-heat input conditions to thermal decay and integrated intensities. The IR based results were validated by processing a 316L cylinder with engineered porosities and detecting the same with ground truth data from computed tomography.",

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Towards process consistency and in-situ evaluation of porosity during laser powder bed additive manufacturing

Abstract

Funding

Keywords

UN SDGs

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