The formation mechanism of metal-ceramic interlayer interface during laser powder bed fusion
Experiments on Laser powder bed fusion (LPBF) of powdered Ti on Al2O3 substrate were conducted and the interface formation was studied using a multi-material fluid dynamics model. Results show that the melt pool is relatively shallow, with relatively flat interlayer interface under LPBF’s conduction...
| Main Authors: | , , , |
|---|---|
| Other Authors: | |
| Format: | Journal Article |
| Language: | English |
| Published: |
2024
|
| Subjects: | |
| Online Access: | https://hdl.handle.net/10356/174328 |
| _version_ | 1811694591938658304 |
|---|---|
| author | Yao, Liming Xiao, Zhongmin Huang, Sheng Ramamurty, Upadrasta |
| author2 | School of Mechanical and Aerospace Engineering |
| author_facet | School of Mechanical and Aerospace Engineering Yao, Liming Xiao, Zhongmin Huang, Sheng Ramamurty, Upadrasta |
| author_sort | Yao, Liming |
| collection | NTU |
| description | Experiments on Laser powder bed fusion (LPBF) of powdered Ti on Al2O3 substrate were conducted and the interface formation was studied using a multi-material fluid dynamics model. Results show that the melt pool is relatively shallow, with relatively flat interlayer interface under LPBF’s conduction mode. In this condition, a thin sheath of molten Al2O3 forms and acts as a lubricating film for the molten Ti, leading to Rayleigh instability due to high flow inertia. Keyhole formation penetrates the Al2O3 substrate, resulting in a wavy interlayer interface. The recoil pressure from the keyhole and overall melt inertia are suppressed by the highly viscous molten Al2O3, thereby improving single-track melt pool stability. However, the thermal expansion coefficient difference between Ti and Al2O3 led to the formation of transverse cracks. Achieving a defect-free metal-on-ceramic single track remains a challenge, despite this study serving as a guide for melt track and interface control. |
| first_indexed | 2024-10-01T07:10:01Z |
| format | Journal Article |
| id | ntu-10356/174328 |
| institution | Nanyang Technological University |
| language | English |
| last_indexed | 2024-10-01T07:10:01Z |
| publishDate | 2024 |
| record_format | dspace |
| spelling | ntu-10356/1743282024-03-30T16:48:04Z The formation mechanism of metal-ceramic interlayer interface during laser powder bed fusion Yao, Liming Xiao, Zhongmin Huang, Sheng Ramamurty, Upadrasta School of Mechanical and Aerospace Engineering Institute of Materials Research and Engineering, A*STAR Engineering Laser powder bed fusion Computational fluid dynamics Experiments on Laser powder bed fusion (LPBF) of powdered Ti on Al2O3 substrate were conducted and the interface formation was studied using a multi-material fluid dynamics model. Results show that the melt pool is relatively shallow, with relatively flat interlayer interface under LPBF’s conduction mode. In this condition, a thin sheath of molten Al2O3 forms and acts as a lubricating film for the molten Ti, leading to Rayleigh instability due to high flow inertia. Keyhole formation penetrates the Al2O3 substrate, resulting in a wavy interlayer interface. The recoil pressure from the keyhole and overall melt inertia are suppressed by the highly viscous molten Al2O3, thereby improving single-track melt pool stability. However, the thermal expansion coefficient difference between Ti and Al2O3 led to the formation of transverse cracks. Achieving a defect-free metal-on-ceramic single track remains a challenge, despite this study serving as a guide for melt track and interface control. Agency for Science, Technology and Research (A*STAR) National Research Foundation (NRF) Published version This research is supported by the Agency for Science, Technology and Research (A*STAR) of Singapore via the Structural Metal Alloys Programme [A18B1b0061], the National Research Foundation, Prime Minister's Office, Singapore under its Medium-Sized Centre funding scheme [001163-00010], and the State Key Laboratory of Robotics and Systems (HIT) [SKLRS-2023-KF-24]. 2024-03-26T06:23:09Z 2024-03-26T06:23:09Z 2023 Journal Article Yao, L., Xiao, Z., Huang, S. & Ramamurty, U. (2023). The formation mechanism of metal-ceramic interlayer interface during laser powder bed fusion. Virtual and Physical Prototyping, 18(1). https://dx.doi.org/10.1080/17452759.2023.2235324 1745-2759 https://hdl.handle.net/10356/174328 10.1080/17452759.2023.2235324 2-s2.0-85167339586 1 18 en A18B1b0061 001163-00010 Virtual and Physical Prototyping © 2023 The Author(s). Published by Informa UK Limited, trading as Taylor & Francis Group. This is an Open Access article distributed under the terms of the Creative Commons Attribution-NonCommercial License (http://creativecommons.org/licenses/by-nc/4.0/), which permits unrestricted non-commercial use, distribution, and reproduction in any medium, provided the original work is properly cited. The terms on which this article has been published allow the posting of the Accepted Manuscript in a repository by the author(s) or with their consent. application/pdf |
| spellingShingle | Engineering Laser powder bed fusion Computational fluid dynamics Yao, Liming Xiao, Zhongmin Huang, Sheng Ramamurty, Upadrasta The formation mechanism of metal-ceramic interlayer interface during laser powder bed fusion |
| title | The formation mechanism of metal-ceramic interlayer interface during laser powder bed fusion |
| title_full | The formation mechanism of metal-ceramic interlayer interface during laser powder bed fusion |
| title_fullStr | The formation mechanism of metal-ceramic interlayer interface during laser powder bed fusion |
| title_full_unstemmed | The formation mechanism of metal-ceramic interlayer interface during laser powder bed fusion |
| title_short | The formation mechanism of metal-ceramic interlayer interface during laser powder bed fusion |
| title_sort | formation mechanism of metal ceramic interlayer interface during laser powder bed fusion |
| topic | Engineering Laser powder bed fusion Computational fluid dynamics |
| url | https://hdl.handle.net/10356/174328 |
| work_keys_str_mv | AT yaoliming theformationmechanismofmetalceramicinterlayerinterfaceduringlaserpowderbedfusion AT xiaozhongmin theformationmechanismofmetalceramicinterlayerinterfaceduringlaserpowderbedfusion AT huangsheng theformationmechanismofmetalceramicinterlayerinterfaceduringlaserpowderbedfusion AT ramamurtyupadrasta theformationmechanismofmetalceramicinterlayerinterfaceduringlaserpowderbedfusion AT yaoliming formationmechanismofmetalceramicinterlayerinterfaceduringlaserpowderbedfusion AT xiaozhongmin formationmechanismofmetalceramicinterlayerinterfaceduringlaserpowderbedfusion AT huangsheng formationmechanismofmetalceramicinterlayerinterfaceduringlaserpowderbedfusion AT ramamurtyupadrasta formationmechanismofmetalceramicinterlayerinterfaceduringlaserpowderbedfusion |