Operando tomographic microscopy during laser-based powder bed fusion of alumina
Abstract Laser-based Powder Bed Fusion (LPBF) of oxide ceramics enables fabrication of objects with complex three-dimensional shapes. However, mechanical properties of dense LPBF-manufactured ceramics are poor due to large amount of structural defects. Here, we perform the operando tomographic micro...
| Main Authors: | , , , , , , , , , |
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| Format: | Article |
| Language: | English |
| Published: |
Nature Portfolio
2023-09-01
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| Series: | Communications Materials |
| Online Access: | https://doi.org/10.1038/s43246-023-00401-3 |
| _version_ | 1797557688623693824 |
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| author | Malgorzata G. Makowska Fabrizio Verga Stefan Pfeiffer Federica Marone Cynthia S. T. Chang Kevin Florio Christian M. Schlepütz Konrad Wegener Thomas Graule Steven Van Petegem |
| author_facet | Malgorzata G. Makowska Fabrizio Verga Stefan Pfeiffer Federica Marone Cynthia S. T. Chang Kevin Florio Christian M. Schlepütz Konrad Wegener Thomas Graule Steven Van Petegem |
| author_sort | Malgorzata G. Makowska |
| collection | DOAJ |
| description | Abstract Laser-based Powder Bed Fusion (LPBF) of oxide ceramics enables fabrication of objects with complex three-dimensional shapes. However, mechanical properties of dense LPBF-manufactured ceramics are poor due to large amount of structural defects. Here, we perform the operando tomographic microscopy during LPBF of a magnetite-modified alumina to gain a deeper understanding of the underlying mechanisms. The effect of the laser energy density on the surface roughness, powder denudation zone and porosity formation mechanisms are investigated. Increasing laser power results in significant increase of the melt pool width, but not its depth and no melt pool depression is observed. Forces due to the recoil pressure are not seen to significantly influence the melt pool dynamics. Increasing power allows to avoid fusion porosity but enhances formation of spherical porosity that is formed by either reaching boiling point of liquid alumina, or by introducing gas bubbles by injection of hollow powder particles into the liquid. |
| first_indexed | 2024-03-10T17:20:11Z |
| format | Article |
| id | doaj.art-4ed459b5170a406daf8a8bb6e2c50bce |
| institution | Directory Open Access Journal |
| issn | 2662-4443 |
| language | English |
| last_indexed | 2024-03-10T17:20:11Z |
| publishDate | 2023-09-01 |
| publisher | Nature Portfolio |
| record_format | Article |
| series | Communications Materials |
| spelling | doaj.art-4ed459b5170a406daf8a8bb6e2c50bce2023-11-20T10:21:42ZengNature PortfolioCommunications Materials2662-44432023-09-014111510.1038/s43246-023-00401-3Operando tomographic microscopy during laser-based powder bed fusion of aluminaMalgorzata G. Makowska0Fabrizio Verga1Stefan Pfeiffer2Federica Marone3Cynthia S. T. Chang4Kevin Florio5Christian M. Schlepütz6Konrad Wegener7Thomas Graule8Steven Van Petegem9Photon Science Division, Paul Scherrer InstitutInstitute of Machine Tools and Manufacturing, ETH ZurichLaboratory for High Performance Ceramics, Empa—Swiss Federal Laboratories for Materials Science and TechnologyPhoton Science Division, Paul Scherrer InstitutTechnology Transfer Centre for Advanced Manufacturing, ANAXAMInstitute of Machine Tools and Manufacturing, ETH ZurichPhoton Science Division, Paul Scherrer InstitutInstitute of Machine Tools and Manufacturing, ETH ZurichLaboratory for High Performance Ceramics, Empa—Swiss Federal Laboratories for Materials Science and TechnologyPhoton Science Division, Paul Scherrer InstitutAbstract Laser-based Powder Bed Fusion (LPBF) of oxide ceramics enables fabrication of objects with complex three-dimensional shapes. However, mechanical properties of dense LPBF-manufactured ceramics are poor due to large amount of structural defects. Here, we perform the operando tomographic microscopy during LPBF of a magnetite-modified alumina to gain a deeper understanding of the underlying mechanisms. The effect of the laser energy density on the surface roughness, powder denudation zone and porosity formation mechanisms are investigated. Increasing laser power results in significant increase of the melt pool width, but not its depth and no melt pool depression is observed. Forces due to the recoil pressure are not seen to significantly influence the melt pool dynamics. Increasing power allows to avoid fusion porosity but enhances formation of spherical porosity that is formed by either reaching boiling point of liquid alumina, or by introducing gas bubbles by injection of hollow powder particles into the liquid.https://doi.org/10.1038/s43246-023-00401-3 |
| spellingShingle | Malgorzata G. Makowska Fabrizio Verga Stefan Pfeiffer Federica Marone Cynthia S. T. Chang Kevin Florio Christian M. Schlepütz Konrad Wegener Thomas Graule Steven Van Petegem Operando tomographic microscopy during laser-based powder bed fusion of alumina Communications Materials |
| title | Operando tomographic microscopy during laser-based powder bed fusion of alumina |
| title_full | Operando tomographic microscopy during laser-based powder bed fusion of alumina |
| title_fullStr | Operando tomographic microscopy during laser-based powder bed fusion of alumina |
| title_full_unstemmed | Operando tomographic microscopy during laser-based powder bed fusion of alumina |
| title_short | Operando tomographic microscopy during laser-based powder bed fusion of alumina |
| title_sort | operando tomographic microscopy during laser based powder bed fusion of alumina |
| url | https://doi.org/10.1038/s43246-023-00401-3 |
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