In situ X-ray imaging of hot cracking and porosity during LPBF of Al-2139 with TiB2 additions and varied process parameters
Laser powder bed fusion (LPBF) additive manufacturing of 2XXX series Al alloys could be used for low volume specialist aerospace components, however, such alloys exhibit hot cracking susceptibility that can lead to component failure. In this study, we show two approaches to suppress the formation of...
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| Format: | Article |
| Language: | English |
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Elsevier
2023-07-01
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| Series: | Materials & Design |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S026412752300446X |
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| author | David T. Rees Chu Lun Alex Leung Joe Elambasseril Sebastian Marussi Saurabh Shah Shashidhara Marathe Milan Brandt Mark Easton Peter D. Lee |
| author_facet | David T. Rees Chu Lun Alex Leung Joe Elambasseril Sebastian Marussi Saurabh Shah Shashidhara Marathe Milan Brandt Mark Easton Peter D. Lee |
| author_sort | David T. Rees |
| collection | DOAJ |
| description | Laser powder bed fusion (LPBF) additive manufacturing of 2XXX series Al alloys could be used for low volume specialist aerospace components, however, such alloys exhibit hot cracking susceptibility that can lead to component failure. In this study, we show two approaches to suppress the formation of hot cracks by controlling solidification behaviour using: (1) TiB2 additions; and (2) optimisation of LPBF process parameters. Using high-speed synchrotron X-ray radiography, we monitored LPBF of Al-2139 in situ, with and without TiB2 under a range of process conditions. In situ X-ray radiography results captured the crack growth over 1.0 ms at a rate of ca. 110 mm s−1, as well as pore evolution, wetting behaviour and build height. High-resolution synchrotron X-ray computed tomography (sCT) was used to measure the volume fraction of defects, e.g. hydrogen pores and microcracks, in the as-built LPBF samples. Our results show adding TiB2 in Al-2139 reduces the volume of cracks by up to 79 % under a volume energy density of 1000 to 5000 J mm−3, as well as reducing the average length, breadth, and surface area of cracks. |
| first_indexed | 2024-03-13T02:56:54Z |
| format | Article |
| id | doaj.art-c32aa128be3e431481b32bcb03a7b715 |
| institution | Directory Open Access Journal |
| issn | 0264-1275 |
| language | English |
| last_indexed | 2024-03-13T02:56:54Z |
| publishDate | 2023-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Materials & Design |
| spelling | doaj.art-c32aa128be3e431481b32bcb03a7b7152023-06-28T04:28:33ZengElsevierMaterials & Design0264-12752023-07-01231112031In situ X-ray imaging of hot cracking and porosity during LPBF of Al-2139 with TiB2 additions and varied process parametersDavid T. Rees0Chu Lun Alex Leung1Joe Elambasseril2Sebastian Marussi3Saurabh Shah4Shashidhara Marathe5Milan Brandt6Mark Easton7Peter D. Lee8UCL Mechanical Engineering, University College London, WC1E 7JE, UK; Research Complex at Harwell, Harwell Campus, Didcot OX11 0FA, UK; Corresponding authors at: Department of Mechanical Engineering, University College London, WC1E 7JE, UK.UCL Mechanical Engineering, University College London, WC1E 7JE, UK; Research Complex at Harwell, Harwell Campus, Didcot OX11 0FA, UK; Corresponding authors at: Department of Mechanical Engineering, University College London, WC1E 7JE, UK.Centre for Additive Manufacturing, RMIT University, PO Box 2476, Melbourne, VIC 3001, AustraliaUCL Mechanical Engineering, University College London, WC1E 7JE, UK; Research Complex at Harwell, Harwell Campus, Didcot OX11 0FA, UKUCL Mechanical Engineering, University College London, WC1E 7JE, UK; Research Complex at Harwell, Harwell Campus, Didcot OX11 0FA, UKDiamond Light Source Ltd, Harwell Campus, Didcot OX11 0DE, UKCentre for Additive Manufacturing, RMIT University, PO Box 2476, Melbourne, VIC 3001, AustraliaCentre for Additive Manufacturing, RMIT University, PO Box 2476, Melbourne, VIC 3001, AustraliaUCL Mechanical Engineering, University College London, WC1E 7JE, UK; Research Complex at Harwell, Harwell Campus, Didcot OX11 0FA, UK; Corresponding authors at: Department of Mechanical Engineering, University College London, WC1E 7JE, UK.Laser powder bed fusion (LPBF) additive manufacturing of 2XXX series Al alloys could be used for low volume specialist aerospace components, however, such alloys exhibit hot cracking susceptibility that can lead to component failure. In this study, we show two approaches to suppress the formation of hot cracks by controlling solidification behaviour using: (1) TiB2 additions; and (2) optimisation of LPBF process parameters. Using high-speed synchrotron X-ray radiography, we monitored LPBF of Al-2139 in situ, with and without TiB2 under a range of process conditions. In situ X-ray radiography results captured the crack growth over 1.0 ms at a rate of ca. 110 mm s−1, as well as pore evolution, wetting behaviour and build height. High-resolution synchrotron X-ray computed tomography (sCT) was used to measure the volume fraction of defects, e.g. hydrogen pores and microcracks, in the as-built LPBF samples. Our results show adding TiB2 in Al-2139 reduces the volume of cracks by up to 79 % under a volume energy density of 1000 to 5000 J mm−3, as well as reducing the average length, breadth, and surface area of cracks.http://www.sciencedirect.com/science/article/pii/S026412752300446XAdditive manufacturingLaser powder bed fusionAluminium alloysX-ray imagingHot cracking |
| spellingShingle | David T. Rees Chu Lun Alex Leung Joe Elambasseril Sebastian Marussi Saurabh Shah Shashidhara Marathe Milan Brandt Mark Easton Peter D. Lee In situ X-ray imaging of hot cracking and porosity during LPBF of Al-2139 with TiB2 additions and varied process parameters Materials & Design Additive manufacturing Laser powder bed fusion Aluminium alloys X-ray imaging Hot cracking |
| title | In situ X-ray imaging of hot cracking and porosity during LPBF of Al-2139 with TiB2 additions and varied process parameters |
| title_full | In situ X-ray imaging of hot cracking and porosity during LPBF of Al-2139 with TiB2 additions and varied process parameters |
| title_fullStr | In situ X-ray imaging of hot cracking and porosity during LPBF of Al-2139 with TiB2 additions and varied process parameters |
| title_full_unstemmed | In situ X-ray imaging of hot cracking and porosity during LPBF of Al-2139 with TiB2 additions and varied process parameters |
| title_short | In situ X-ray imaging of hot cracking and porosity during LPBF of Al-2139 with TiB2 additions and varied process parameters |
| title_sort | in situ x ray imaging of hot cracking and porosity during lpbf of al 2139 with tib2 additions and varied process parameters |
| topic | Additive manufacturing Laser powder bed fusion Aluminium alloys X-ray imaging Hot cracking |
| url | http://www.sciencedirect.com/science/article/pii/S026412752300446X |
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