In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging
Electron Beam Powder Bed Fusion (PBF-EB) is an Additive Manufacturing (AM) method that utilizes an electron beam to melt and consolidate metal powder. The beam, combined with a backscattered electron detector, enables advanced process monitoring, a method termed Electron Optical Imaging (ELO). ELO i...
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| Format: | Article |
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MDPI AG
2023-06-01
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| Series: | Materials |
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| Online Access: | https://www.mdpi.com/1996-1944/16/12/4220 |
| _version_ | 1797593714985533440 |
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| author | Martin Gardfjell Marcel Reith Martin Franke Carolin Körner |
| author_facet | Martin Gardfjell Marcel Reith Martin Franke Carolin Körner |
| author_sort | Martin Gardfjell |
| collection | DOAJ |
| description | Electron Beam Powder Bed Fusion (PBF-EB) is an Additive Manufacturing (AM) method that utilizes an electron beam to melt and consolidate metal powder. The beam, combined with a backscattered electron detector, enables advanced process monitoring, a method termed Electron Optical Imaging (ELO). ELO is already known to provide great topographical information, but its capabilities regarding material contrast are less studied. In this article the extents of material contrast using ELO are investigated, focusing mainly on identifying powder contamination. It will be shown that an ELO detector is capable of distinguishing a single 100 μ<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mi mathvariant="normal">m</mi></semantics></math></inline-formula> foreign powder particle, during an PBF-EB process, if the backscattering coefficient of the inclusion is sufficiently higher than its surroundings. Additionally, it is investigated how the material contrast can be used for material characterization. A mathematical framework is provided to describe the relationship between the signal intensity in the detector and the effective atomic number <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mi mathvariant="normal">Z</mi><mi>eff</mi></msup></semantics></math></inline-formula> of the imaged alloy. The approach is verified with empirical data from twelve different materials, demonstrating that the effective atomic number of an alloy can be predicted to within one atomic number from its ELO intensity. |
| first_indexed | 2024-03-11T02:13:24Z |
| format | Article |
| id | doaj.art-59b3df2fa36f43a5bd74870b1da3cd9f |
| institution | Directory Open Access Journal |
| issn | 1996-1944 |
| language | English |
| last_indexed | 2024-03-11T02:13:24Z |
| publishDate | 2023-06-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Materials |
| spelling | doaj.art-59b3df2fa36f43a5bd74870b1da3cd9f2023-11-18T11:23:10ZengMDPI AGMaterials1996-19442023-06-011612422010.3390/ma16124220In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical ImagingMartin Gardfjell0Marcel Reith1Martin Franke2Carolin Körner3Neue Materialien Fürth GmbH, 90762 Fürth, GermanyNeue Materialien Fürth GmbH, 90762 Fürth, GermanyNeue Materialien Fürth GmbH, 90762 Fürth, GermanyMaterials Science and Engineering for Metals (WTM), Martensstr. 5., 91058 Erlangen, GermanyElectron Beam Powder Bed Fusion (PBF-EB) is an Additive Manufacturing (AM) method that utilizes an electron beam to melt and consolidate metal powder. The beam, combined with a backscattered electron detector, enables advanced process monitoring, a method termed Electron Optical Imaging (ELO). ELO is already known to provide great topographical information, but its capabilities regarding material contrast are less studied. In this article the extents of material contrast using ELO are investigated, focusing mainly on identifying powder contamination. It will be shown that an ELO detector is capable of distinguishing a single 100 μ<inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><mi mathvariant="normal">m</mi></semantics></math></inline-formula> foreign powder particle, during an PBF-EB process, if the backscattering coefficient of the inclusion is sufficiently higher than its surroundings. Additionally, it is investigated how the material contrast can be used for material characterization. A mathematical framework is provided to describe the relationship between the signal intensity in the detector and the effective atomic number <inline-formula><math xmlns="http://www.w3.org/1998/Math/MathML" display="inline"><semantics><msup><mi mathvariant="normal">Z</mi><mi>eff</mi></msup></semantics></math></inline-formula> of the imaged alloy. The approach is verified with empirical data from twelve different materials, demonstrating that the effective atomic number of an alloy can be predicted to within one atomic number from its ELO intensity.https://www.mdpi.com/1996-1944/16/12/4220Additive ManufacturingElectron Beam Powder Bed FusionProcess MonitoringBackscattered Electron DetectionElectron Optical ImagingPowder Contamination |
| spellingShingle | Martin Gardfjell Marcel Reith Martin Franke Carolin Körner In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging Materials Additive Manufacturing Electron Beam Powder Bed Fusion Process Monitoring Backscattered Electron Detection Electron Optical Imaging Powder Contamination |
| title | In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging |
| title_full | In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging |
| title_fullStr | In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging |
| title_full_unstemmed | In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging |
| title_short | In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging |
| title_sort | in situ inclusion detection and material characterization in an electron beam powder bed fusion process using electron optical imaging |
| topic | Additive Manufacturing Electron Beam Powder Bed Fusion Process Monitoring Backscattered Electron Detection Electron Optical Imaging Powder Contamination |
| url | https://www.mdpi.com/1996-1944/16/12/4220 |
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