In situ X-ray imaging of hot cracking and porosity during LPBF of Al-2139 with TiB2 additions and varied process parameters

Rees, David Tien; Leung, Chu Lun Alex; Elambasseril, Joe; Marussi, Sebastian; Shah, Saurabh; Marathe, Shashidhara; Brandt, Milan; Easton, Mark; Lee, Peter

doi:10.1016/j.matdes.2023.112031

Cited by 18 publications

(5 citation statements)

References 53 publications

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“…During solid-state processing, Mishra et al [23] described the peak temperature at the workpiece as being lower than the alloy melting temperature (60-90% T m ). These parts do not suffer from solidification defects such as hot cracking or porosity noted for fusion processes such as LPBF [24], allowing AM of non-weldable Al alloy grades. Rivera et al [25] applied AFSD to fabricate AA2219 with no defects and high mechanical properties.…”

Section: Solid-state Based Am Processes (Deformation or Plasticity Ba...mentioning

confidence: 99%

Recycled Aluminium Feedstock in Metal Additive Manufacturing: A State of the Art Review

Yakubov,

Ostergaard,

Bhagavath

et al. 2024

Preprint

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Section: Solid-state Based Am Processes (Deformation or Plasticity Ba...mentioning

confidence: 99%

Recycled Aluminium Feedstock in Metal Additive Manufacturing: A State of the Art Review

Yakubov,

Ostergaard,

Bhagavath

et al. 2024

Preprint

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“…However, the addition of particles can achieve the elimination of hot cracks for some LPBF-fabricated alloys [201][202][203]. For instance, Liu et al [204] employed TiC nanoparticles and TiH 2 powder as reinforcements to achieve grain refinement and crack inhibition of LPBF-fabricated Al alloys, and the formation of L1 2 -Al 3 Ti particles could provide heterogeneous nucleation sites for matrix grains.…”

Section: Elimination Of Hot Cracks Via the Addition Of Reinforced Par...mentioning

confidence: 99%

Strategies and Outlook on Metal Matrix Composites Produced Using Laser Powder Bed Fusion: A Review

Kim,

Fang,

Kim

et al. 2023

Metals

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Particle-reinforced metal matrix composites (MMCs) produced using the laser powder bed fusion (LPBF) technique have gained considerable attention because of their distinct attributes and properties in comparison with conventional manufacturing methods. Nevertheless, significant challenges persist with LPBF-fabricated MMCs: more design parameters over commercially available alloys and several defects resulting from inappropriate process conditions. These challenges arise from the intricate interaction of material- and process-related phenomena, requiring a fundamental understanding of the LPBF process to elucidate the microstructural evolution and underlying mechanisms of strengthening. This paper provides a comprehensive overview of these intricate phenomena and mechanisms, aiming to mitigate the process-related defects and facilitate the design of MMCs with enhanced mechanical properties. The material processing approach was suggested, covering from material design and LPBF to postprocessing. Furthermore, the role of in situ heat treatment on the microstructure evolution of MMCs was clarified, and several novel, potential strengthening theories were discussed for the LPBF-fabricated MMCs. The suggested strategies to address the challenges and design high-performance MMCs will offer an opportunity to develop promising LPBF-fabricated MMCs, while overcoming the material limitations of LPBF.

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“…Much of the existing literature captures the spatter and vapour plume over the powder surface using in situ highspeed optical [14,22] or Schlieren imaging [29], which lack details on the changes of vapour depression or keyhole morphology during LPBF. Synchrotron x-ray sources can be used to capture both spatter and melt pool dynamics during LPBF at exceptional temporal resolution (up to 1 MHz) [30][31][32][33][34]. Combining synchrotron x-ray radiography and Schlieren imaging suggests that the vapour ejection angle is highly related to the morphology of the depression zone/keyhole [35]; however, the influence of keyhole morphology on spatter formation remains not well understood.…”

Section: Introductionmentioning

confidence: 99%

Correlative spatter and vapour depression dynamics during laser powder bed fusion of an Al-Fe-Zr alloy

Guo,

Lambert-Garcia,

Hocine

et al. 2024

Int. J. Extrem. Manuf.

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Spatter during laser powder bed fusion (LPBF) can induce surface defects, impacting the fatigue performance of the fabricated components. Here, we reveal and explain the links between vapour depression shape and spatter dynamics during LPBF of an Al-Fe-Zr aluminium alloy using high-speed synchrotron X-ray imaging. We quantify the number, trajectory angle, velocity, and kinetic energy of the spatter as a function of vapour depression zone/keyhole morphology under industry-relevant processing conditions. The depression zone/keyhole morphology was found to influence the spatter ejection angle in keyhole versus conduction melting modes: (i) the vapour-pressure driven plume in conduction mode with a quasi-semi-circular depression zone leads to backward spatter whereas (ii) the keyhole rear wall redirects the gas/vapour flow to cause vertical spatter ejection and rear rim droplet spatter. Increasing the opening of the keyhole or vapour depression zone can reduce entrainment of solid spatter. We discover a spatter-induced crater mechanism in which small spatter particles are accelerated towards the powder bed after laser-spatter interaction, inducing powder denudation and cavities on the printed surface. By quantifying these laser-spatter interactions, we suggest a printing strategy for minimising defects and improving the surface quality of LPBF parts.

show abstract

In situ X-ray imaging of hot cracking and porosity during LPBF of Al-2139 with TiB2 additions and varied process parameters

Cited by 18 publications

References 53 publications

Recycled Aluminium Feedstock in Metal Additive Manufacturing: A State of the Art Review

Recycled Aluminium Feedstock in Metal Additive Manufacturing: A State of the Art Review

Strategies and Outlook on Metal Matrix Composites Produced Using Laser Powder Bed Fusion: A Review

Correlative spatter and vapour depression dynamics during laser powder bed fusion of an Al-Fe-Zr alloy

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