Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging

Zachary A. Young; Meelap M. Coday; Qilin Guo; Minglei Qu; S. Mohammad H. Hojjatzadeh; Luis I. Escano; Kamel Fezzaa; Tao Sun; Lianyi Chen

doi:10.3390/ma15020530

Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging

Zachary A. Young, Meelap M. Coday, Qilin Guo, Minglei Qu, S. Mohammad H. Hojjatzadeh, Luis I. Escano, Kamel Fezzaa, Tao Sun, Lianyi Chen

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

11 Scopus citations

Abstract

Selective laser melting (SLM) additive manufacturing (AM) exhibits uncertainties, where variations in build quality are present despite utilizing the same optimized processing parameters. In this work, we identify the sources of uncertainty in SLM process by in-situ characterization of SLM dynamics induced by small variations in processing parameters. We show that variations in the laser beam size, laser power, laser scan speed, and powder layer thickness result in significant variations in the depression zone, melt pool, and spatter behavior. On average, a small deviation of only ~5% from the optimized/reference laser processing parameter resulted in a ~10% or greater change in the depression zone and melt pool geometries. For spatter dynamics, small variation (10 µm, 11%) of the laser beam size could lead to over 40% change in the overall volume of the spatter generated. The responses of the SLM dynamics to small variations of processing parameters revealed in this work are useful for understanding the process uncertainties in the SLM process.

Original language	English
Article number	530
Journal	Materials
Volume	15
Issue number	2
DOIs	https://doi.org/10.3390/ma15020530
State	Published - Jan 1 2022
Externally published	Yes

Funding

Funding: This research used resources of the Advanced Photon Source, a U.S. Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02-06CH11357. This work is funded by the Boeing Company through the Center for Aerospace Manufacturing Technology (CAMT) at Missouri University of Science and Technology, and the US National Science Foundation. Z.Y. is supported by the Graduate Assistance in Areas of National Need (GAANN) program of the U.S. Department of Education.

Keywords

Additive manufacturing
Laser powder bed fusion
Melt pool dynamics
Quality uncertainty
Selective laser melting
Spatter

UN SDGs

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

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10.3390/ma15020530

Cite this

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title = "Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging",

abstract = "Selective laser melting (SLM) additive manufacturing (AM) exhibits uncertainties, where variations in build quality are present despite utilizing the same optimized processing parameters. In this work, we identify the sources of uncertainty in SLM process by in-situ characterization of SLM dynamics induced by small variations in processing parameters. We show that variations in the laser beam size, laser power, laser scan speed, and powder layer thickness result in significant variations in the depression zone, melt pool, and spatter behavior. On average, a small deviation of only ~5% from the optimized/reference laser processing parameter resulted in a ~10% or greater change in the depression zone and melt pool geometries. For spatter dynamics, small variation (10 µm, 11%) of the laser beam size could lead to over 40% change in the overall volume of the spatter generated. The responses of the SLM dynamics to small variations of processing parameters revealed in this work are useful for understanding the process uncertainties in the SLM process.",

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author = "Young, {Zachary A.} and Coday, {Meelap M.} and Qilin Guo and Minglei Qu and Hojjatzadeh, {S. Mohammad H.} and Escano, {Luis I.} and Kamel Fezzaa and Tao Sun and Lianyi Chen",

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AU - Young, Zachary A.

AU - Coday, Meelap M.

AU - Guo, Qilin

AU - Qu, Minglei

AU - Hojjatzadeh, S. Mohammad H.

AU - Escano, Luis I.

AU - Fezzaa, Kamel

AU - Sun, Tao

AU - Chen, Lianyi

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N2 - Selective laser melting (SLM) additive manufacturing (AM) exhibits uncertainties, where variations in build quality are present despite utilizing the same optimized processing parameters. In this work, we identify the sources of uncertainty in SLM process by in-situ characterization of SLM dynamics induced by small variations in processing parameters. We show that variations in the laser beam size, laser power, laser scan speed, and powder layer thickness result in significant variations in the depression zone, melt pool, and spatter behavior. On average, a small deviation of only ~5% from the optimized/reference laser processing parameter resulted in a ~10% or greater change in the depression zone and melt pool geometries. For spatter dynamics, small variation (10 µm, 11%) of the laser beam size could lead to over 40% change in the overall volume of the spatter generated. The responses of the SLM dynamics to small variations of processing parameters revealed in this work are useful for understanding the process uncertainties in the SLM process.

AB - Selective laser melting (SLM) additive manufacturing (AM) exhibits uncertainties, where variations in build quality are present despite utilizing the same optimized processing parameters. In this work, we identify the sources of uncertainty in SLM process by in-situ characterization of SLM dynamics induced by small variations in processing parameters. We show that variations in the laser beam size, laser power, laser scan speed, and powder layer thickness result in significant variations in the depression zone, melt pool, and spatter behavior. On average, a small deviation of only ~5% from the optimized/reference laser processing parameter resulted in a ~10% or greater change in the depression zone and melt pool geometries. For spatter dynamics, small variation (10 µm, 11%) of the laser beam size could lead to over 40% change in the overall volume of the spatter generated. The responses of the SLM dynamics to small variations of processing parameters revealed in this work are useful for understanding the process uncertainties in the SLM process.

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KW - Selective laser melting

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Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging

Abstract

Funding

Keywords

UN SDGs

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