Laser-induced plume investigated by finite element modelling and scaling of particle entrainment in laser powder bed fusion

Mayi, Yaasin; Dal, Morgan; Peyre, Patrice; Bellet, Michel; Metton, Charlotte; Moriconi, Clara; Fabbro, R.

doi:10.1088/1361-6463/ab5900

Cited by 39 publications

(24 citation statements)

References 48 publications

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“…This phenomenon was also pointed out experimentally by (Bidare, 2018) and suspected by (Mayi et al, 2019) using numerical simulation. During the keyhole formation and the vaporisation of the metal, a radial flow (of protective gas) directed toward the melt pool is induced Fig.…”

Section: Argon Versus Heliumsupporting

confidence: 66%

“…Under argon, a large volume of vapour expands as a cloud whereas under helium it takes the form of a strongly oriented vapour beam. This suggests a faster expansion speed under helium due to its lower density (Mayi et al, 2019). In that case, the vapour is expanding freely and is less confined by the surrounding gas than in argon.…”

Section: Analysis Of the Vapour Plumementioning

confidence: 99%

“…(Matthews et al, 2016) which is the dragging force for denudation. Because the associated speed flow was found to be approximately two times faster under helium because of its lower density (Mayi et al, 2019), the resulting dragging force F t ∝1/2 ρSU² (for a particle of projected surface S in a gas of density ρ and velocity U) is therefore able to transport more powder towards the melt pool in helium. That enhanced powder feeding under helium is responsible for the difference in morphology: L-PBF beads are comparatively larger in their upper part (Fig.…”

Section: Argon Versus Heliummentioning

confidence: 99%

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Influence of gas atmosphere (Ar or He) on the laser powder bed fusion of a Ni-based alloy

Traore

Schneider

Koutiri

et al. 2021

Journal of Materials Processing Technology

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The gaseous atmosphere plays a major role in the quality of the manufactured parts in Laser Powder Bed Fusion (L-PBF) by protecting the metal from high temperature oxidation. If argon and nitrogen are the most commonly used gases, helium has almost never been considered as a possible candidate as a chemically inert shielding gas. To provide a better understanding of the influence of the gas atmosphere on the process stability, a comparative study of L-PBF manufacturing under argon and helium atmospheres has been carried out, considering a nickelbased alloy Inconel® 625 and a single bead configuration. To this end, in-situ process measurements were carried out on a dedicated experimental setup. The melt pool behaviour, the expansion of the vapour plume and the amount of spatters were evaluated with high-speed imaging for the two gases considered, together with the final L-PBF bead dimensions. Results were also compared to single fusion beads carried out in an industrial L-PBF machine for a comparable range of volume energy densities. The influence of the shielding atmosphere on L-PBF single beads was as follows: (1) dimensions of beads were shown to be constant whatever the gas; (2) fewer and smaller spatters were produced under helium atmosphere, especially for high volume energy densities. Physical mechanisms were then discussed to understand those specific effects.

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Section: Argon Versus Heliumsupporting

confidence: 66%

Section: Analysis Of the Vapour Plumementioning

confidence: 99%

Section: Argon Versus Heliummentioning

confidence: 99%

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Influence of gas atmosphere (Ar or He) on the laser powder bed fusion of a Ni-based alloy

Traore

Schneider

Koutiri

et al. 2021

Journal of Materials Processing Technology

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“…The spattering power is measured from x-ray imaging series for bare plate experiments (Supplementary Text). The spattering is more frequent in laser powder bed fusion process because of the particle entrainment effect (23), which might lead to higher spattering power loss.…”

Section: The Scaling Parameter Ke M L Dmentioning

confidence: 99%

Universal scaling laws of keyhole stability and porosity in 3D printing of metals

Gan¹,

Kafka²,

Parab

et al. 2020

Preprint

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We leverage ultrahigh-speed synchrotron x-ray imaging and high-fidelity multiphysics modeling to identify strikingly simple yet universal scaling laws for keyhole stability and porosity in metal three-dimensional (3D) printing. The laws apply broadly and remain accurate for different materials, processing conditions, and printing machines. We define a new dimensionless number, the Keyhole number, to predict aspect ratio of a keyhole and the morphological transition from stable at low Keyhole number to chaotic at high Keyhole number. Furthermore, we discover inherent correlation between keyhole stability and porosity formation in metal 3D printing. By reducing the dimensions of the formulation of these challenging problems, the compact scaling laws will aid process optimization and defect elimination during metal 3D printing, and potentially lead to a quantitative predictive framework.

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“…by temperature gradient mechanism [15,34,39]. Based on this metallurgical behavior, pre-solidified material underneath the melted layer is heated up rapidly upon laser irradiation, which readily expands, but is constricted by the cold and rigid portions of the solidified piece, repeated in multiple cycles [40,41]. It was also observed that when the samples were rotated around the Z axis by 45° (e.g., Figure 9b), the recoater does not suddenly meet a long section, reducing the risks of crashes.…”

Section: Manufacturing Evaluationmentioning

confidence: 99%

Improving the Mechanical Strength of Dental Applications and Lattice Structures SLM Processed

Cosma

Kessler²,

Gebhardt

et al. 2020

Materials

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To manufacture custom medical parts or scaffolds with reduced defects and high mechanical characteristics, new research on optimizing the selective laser melting (SLM) parameters are needed. In this work, a biocompatible powder, 316L stainless steel, is characterized to understand the particle size, distribution, shape and flowability. Examination revealed that the 316L particles are smooth, nearly spherical, their mean diameter is 39.09 μm and just 10% of them hold a diameter less than 21.18 μm. SLM parameters under consideration include laser power up to 200 W, 250–1500 mm/s scanning speed, 80 μm hatch spacing, 35 μm layer thickness and a preheated platform. The effect of these on processability is evaluated. More than 100 samples are SLM-manufactured with different process parameters. The tensile results show that is possible to raise the ultimate tensile strength up to 840 MPa, adapting the SLM parameters for a stable processability, avoiding the technological defects caused by residual stress. Correlating with other recent studies on SLM technology, the tensile strength is 20% improved. To validate the SLM parameters and conditions established, complex bioengineering applications such as dental bridges and macro-porous grafts are SLM-processed, demonstrating the potential to manufacture medical products with increased mechanical resistance made of 316L.

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Laser-induced plume investigated by finite element modelling and scaling of particle entrainment in laser powder bed fusion

Abstract: FABBRO-Laser-induced plume investigated by finite element modelling and scaling of particle entrainment in laser powder bed fusion

Cited by 39 publications

References 48 publications

Influence of gas atmosphere (Ar or He) on the laser powder bed fusion of a Ni-based alloy

Influence of gas atmosphere (Ar or He) on the laser powder bed fusion of a Ni-based alloy

Universal scaling laws of keyhole stability and porosity in 3D printing of metals

Improving the Mechanical Strength of Dental Applications and Lattice Structures SLM Processed

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