Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging
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...
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MDPI AG
2022-01-01
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| Online Access: | https://www.mdpi.com/1996-1944/15/2/530 |
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| author | Zachary A. Young Meelap M. Coday Qilin Guo Minglei Qu S. Mohammad H. Hojjatzadeh Luis I. Escano Kamel Fezzaa Tao Sun Lianyi Chen |
| author_facet | Zachary A. Young Meelap M. Coday Qilin Guo Minglei Qu S. Mohammad H. Hojjatzadeh Luis I. Escano Kamel Fezzaa Tao Sun Lianyi Chen |
| author_sort | Zachary A. Young |
| collection | DOAJ |
| description | 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 <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mrow><mi mathvariant="sans-serif">μ</mi><mi mathvariant="normal">m</mi></mrow></mrow></semantics></math></inline-formula>, 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. |
| first_indexed | 2024-03-10T01:03:22Z |
| format | Article |
| id | doaj.art-2a94905984074ac1aecde0570251ea4a |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-10T01:03:22Z |
| publishDate | 2022-01-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-2a94905984074ac1aecde0570251ea4a2023-11-23T14:30:39ZengMDPI AGMaterials1996-19442022-01-0115253010.3390/ma15020530Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray ImagingZachary A. Young0Meelap M. Coday1Qilin Guo2Minglei Qu3S. Mohammad H. Hojjatzadeh4Luis I. Escano5Kamel Fezzaa6Tao Sun7Lianyi Chen8Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO 65409, USADepartment of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO 65409, USADepartment of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI 53706, USADepartment of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI 53706, USADepartment of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI 53706, USADepartment of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI 53706, USAX-ray Science Division, Advanced Photon Source, Argonne National Laboratory, Lemont, IL 60439, USADepartment of Materials Science and Engineering, University of Virginia, Charlottesville, VA 22904, USADepartment of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Rolla, MO 65409, USASelective 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 <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mrow><mrow><mi mathvariant="sans-serif">μ</mi><mi mathvariant="normal">m</mi></mrow></mrow></semantics></math></inline-formula>, 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.https://www.mdpi.com/1996-1944/15/2/530selective laser meltinglaser powder bed fusionadditive manufacturingspattermelt pool dynamicsquality uncertainty |
| spellingShingle | Zachary A. Young Meelap M. Coday Qilin Guo Minglei Qu S. Mohammad H. Hojjatzadeh Luis I. Escano Kamel Fezzaa Tao Sun Lianyi Chen Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging Materials selective laser melting laser powder bed fusion additive manufacturing spatter melt pool dynamics quality uncertainty |
| title | Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging |
| title_full | Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging |
| title_fullStr | Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging |
| title_full_unstemmed | Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging |
| title_short | Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging |
| title_sort | uncertainties induced by processing parameter variation in selective laser melting of ti6al4v revealed by in situ x ray imaging |
| topic | selective laser melting laser powder bed fusion additive manufacturing spatter melt pool dynamics quality uncertainty |
| url | https://www.mdpi.com/1996-1944/15/2/530 |
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