Analysis of defect generation in Ti–6Al–4V parts made using powder bed fusion additive manufacturing processes
Ti–6Al–4V parts made using additive manufacturing processes such as selective laser melting (SLM) and electron beam melting (EBM) are subject to the inclusion of defects. This study purposely fabricated Ti–6Al–4V samples with defects by varying process parameters from the factory default settings in...
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| Published in | Additive manufacturing Vol. 1-4; pp. 87 - 98 |
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| Main Authors | , , , , |
| Format | Journal Article |
| Language | English |
| Published |
Elsevier B.V
01.10.2014
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| Subjects | |
| Online Access | Get full text |
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| Abstract | Ti–6Al–4V parts made using additive manufacturing processes such as selective laser melting (SLM) and electron beam melting (EBM) are subject to the inclusion of defects. This study purposely fabricated Ti–6Al–4V samples with defects by varying process parameters from the factory default settings in both SLM and EBM systems. Process parameters are classified according to their tendency to create certain types of porosity. Finally, defect characteristics are discussed with respect to defect generation mechanisms; and effective process windows for SLM and EBM system are discussed. |
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| AbstractList | Ti–6Al–4V parts made using additive manufacturing processes such as selective laser melting (SLM) and electron beam melting (EBM) are subject to the inclusion of defects. This study purposely fabricated Ti–6Al–4V samples with defects by varying process parameters from the factory default settings in both SLM and EBM systems. Process parameters are classified according to their tendency to create certain types of porosity. Finally, defect characteristics are discussed with respect to defect generation mechanisms; and effective process windows for SLM and EBM system are discussed. |
| Author | Rafi, Khalid Gu, Hengfeng Stucker, Brent Gong, Haijun Starr, Thomas |
| Author_xml | – sequence: 1 givenname: Haijun surname: Gong fullname: Gong, Haijun organization: J.B. Speed School of Engineering, University of Louisville, Louisville, KY, United States – sequence: 2 givenname: Khalid surname: Rafi fullname: Rafi, Khalid organization: J.B. Speed School of Engineering, University of Louisville, Louisville, KY, United States – sequence: 3 givenname: Hengfeng orcidid: 0000-0003-4027-2775 surname: Gu fullname: Gu, Hengfeng organization: J.B. Speed School of Engineering, University of Louisville, Louisville, KY, United States – sequence: 4 givenname: Thomas surname: Starr fullname: Starr, Thomas organization: J.B. Speed School of Engineering, University of Louisville, Louisville, KY, United States – sequence: 5 givenname: Brent orcidid: 0000-0001-6215-6383 surname: Stucker fullname: Stucker, Brent email: brent.stucker@louisville.edu organization: J.B. Speed School of Engineering, University of Louisville, Louisville, KY, United States |
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| References | Gong, Gu, Zeng, Dilip, Pal, Stucker (bib0075) 2014 King, Anderson, Ferencz, Hodge, Kamath, Khairallah (bib0070) 2014 Hiemenz (bib0010) 2007; 165 Soboyejo, Srivatsan (bib0015) 2006 Gibson, Rosen, Stucker (bib0005) 2009 Zäh, Lutzmann (bib0060) 2010; 4 Kruth, Froyen, Van Vaerenbergh (bib0080) 2004; 149 Spierings, Schneider (bib0045) 2011; 17 Puebla, Murr, Gaytan, Martinez, Medina, Wicker (bib0050) 2012; 3 Kahnert, Lutzmann, Zaeh (bib0030) 2007 Li (bib0065) 2006; 41 Sigl, Lutzmann, Zaeh (bib0090) 2006 Kong, Tuck, Ashcroft, Wildman, Hague (bib0095) 2011 Biamino, Penna, Ackelid, Sabbadini, Tassa, Fino (bib0025) 2011; 19 Von Allmen (bib0085) 1987 Gong, Rafi, Starr, Stucker (bib0035) 2012 Murr, Quinones, Gaytan, Lopez, Rodela, Martinez (bib0100) 2009; 2 Thijs, Verhaeghe, Craeghs, Van Humbeeck, Kruth (bib0040) 2010; 58 Schwerdtfeger, Singer, Körner (bib0055) 2012; 18 Sercombe, Jones, Day, Kop (bib0020) 2008; 14 Soboyejo (10.1016/j.addma.2014.08.002_bib0015) 2006 Spierings (10.1016/j.addma.2014.08.002_bib0045) 2011; 17 Kong (10.1016/j.addma.2014.08.002_bib0095) 2011 Li (10.1016/j.addma.2014.08.002_bib0065) 2006; 41 Sigl (10.1016/j.addma.2014.08.002_bib0090) 2006 Biamino (10.1016/j.addma.2014.08.002_bib0025) 2011; 19 Gong (10.1016/j.addma.2014.08.002_bib0035) 2012 Murr (10.1016/j.addma.2014.08.002_bib0100) 2009; 2 Gong (10.1016/j.addma.2014.08.002_bib0075) 2014 Kahnert (10.1016/j.addma.2014.08.002_bib0030) 2007 Gibson (10.1016/j.addma.2014.08.002_bib0005) 2009 Sercombe (10.1016/j.addma.2014.08.002_bib0020) 2008; 14 King (10.1016/j.addma.2014.08.002_bib0070) 2014 Kruth (10.1016/j.addma.2014.08.002_bib0080) 2004; 149 Hiemenz (10.1016/j.addma.2014.08.002_bib0010) 2007; 165 Zäh (10.1016/j.addma.2014.08.002_bib0060) 2010; 4 Thijs (10.1016/j.addma.2014.08.002_bib0040) 2010; 58 Puebla (10.1016/j.addma.2014.08.002_bib0050) 2012; 3 Von Allmen (10.1016/j.addma.2014.08.002_bib0085) 1987 Schwerdtfeger (10.1016/j.addma.2014.08.002_bib0055) 2012; 18 |
| References_xml | – start-page: 146 year: 1987 end-page: 174 ident: bib0085 article-title: Laser–beam interactions with materials – volume: 14 start-page: 300 year: 2008 end-page: 304 ident: bib0020 article-title: Heat treatment of Ti–6Al–7Nb components produced by selective laser melting publication-title: Rapid Prototyping J – year: 2014 ident: bib0070 article-title: Modeling and simulation of metal additive manufacturing for accelerated certification publication-title: Additive manufacturing consortium winter meeting – start-page: 88 year: 2007 end-page: 99 ident: bib0030 article-title: Layer formations in electron beam sintering publication-title: Solid freeform fabrication symposium – start-page: 359 year: 2006 end-page: 400 ident: bib0015 article-title: Advanced structural materials: properties, design optimization, and applications – start-page: 499 year: 2012 end-page: 506 ident: bib0035 article-title: Effect of defects on fatigue tests of as-built Ti–6Al–4V parts fabricated by selective laser melting publication-title: Solid freeform fabrication symposium – volume: 17 start-page: 380 year: 2011 end-page: 386 ident: bib0045 article-title: Comparison of density measurement techniques for additive manufactured metallic parts publication-title: Rapid Prototyping J – volume: 58 start-page: 3303 year: 2010 end-page: 3312 ident: bib0040 article-title: A study of the microstructural evolution during selective laser melting of Ti–6Al–4V publication-title: Acta Mater – volume: 3 start-page: 259 year: 2012 end-page: 264 ident: bib0050 article-title: Effect of melt scan rate on microstructure and macrostructure for electron beam melting of Ti–6Al–4V publication-title: Mater Sci Appl – start-page: 475 year: 2011 end-page: 483 ident: bib0095 article-title: High density Ti6Al4V via SLM processing: microstructure and mechanical properties publication-title: Solid freeform fabrication symposium – start-page: 464 year: 2006 end-page: 477 ident: bib0090 article-title: 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10.1016/j.addma.2014.08.002_bib0020 article-title: Heat treatment of Ti–6Al–7Nb components produced by selective laser melting publication-title: Rapid Prototyping J doi: 10.1108/13552540810907974 – year: 2014 ident: 10.1016/j.addma.2014.08.002_bib0075 article-title: Melt pool characterization for selective laser melting of Ti–6Al–4V pre-alloyed powder – volume: 149 start-page: 616 year: 2004 ident: 10.1016/j.addma.2014.08.002_bib0080 article-title: Selective laser melting of iron-based powder publication-title: J Mater Process Technol doi: 10.1016/j.jmatprotec.2003.11.051 – volume: 19 start-page: 776 year: 2011 ident: 10.1016/j.addma.2014.08.002_bib0025 article-title: Electron beam melting of Ti–48Al–2Cr–2Nb alloy: microstructure and mechanical properties investigation publication-title: Intermetallics doi: 10.1016/j.intermet.2010.11.017 – volume: 18 start-page: 259 year: 2012 ident: 10.1016/j.addma.2014.08.002_bib0055 article-title: In situ flaw detection by IR-imaging during electron beam melting publication-title: Rapid Prototyping J doi: 10.1108/13552541211231572 – volume: 165 start-page: 45 year: 2007 ident: 10.1016/j.addma.2014.08.002_bib0010 article-title: Electron beam melting publication-title: Adv Mater Process – volume: 17 start-page: 380 year: 2011 ident: 10.1016/j.addma.2014.08.002_bib0045 article-title: Comparison of density measurement techniques for additive manufactured metallic parts publication-title: Rapid Prototyping J doi: 10.1108/13552541111156504 – start-page: 475 year: 2011 ident: 10.1016/j.addma.2014.08.002_bib0095 article-title: High density Ti6Al4V via SLM processing: microstructure and mechanical properties – volume: 4 start-page: 15 year: 2010 ident: 10.1016/j.addma.2014.08.002_bib0060 article-title: Modelling and simulation of electron beam melting publication-title: Prod Eng Res Dev doi: 10.1007/s11740-009-0197-6 – volume: 58 start-page: 3303 year: 2010 ident: 10.1016/j.addma.2014.08.002_bib0040 article-title: A study of the 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| Title | Analysis of defect generation in Ti–6Al–4V parts made using powder bed fusion additive manufacturing processes |
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