Subsurface Cooling Rates and Microstructural Response during Laser Based Metal Additive Manufacturing

Laser powder bed fusion (LPBF) is a method of additive manufacturing characterized by the rapid scanning of a high powered laser over a thin bed of metallic powder to create a single layer, which may then be built upon to form larger structures. Much of the melting, resolidification, and subsequent...

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Published inScientific reports Vol. 10; no. 1; p. 1981
Main Authors Thampy, Vivek, Fong, Anthony Y., Calta, Nicholas P., Wang, Jenny, Martin, Aiden A., Depond, Philip J., Kiss, Andrew M., Guss, Gabe, Xing, Qingfeng, Ott, Ryan T., van Buuren, Anthony, Toney, Michael F., Weker, Johanna Nelson, Kramer, Matthew J., Matthews, Manyalibo J., Tassone, Christopher J., Stone, Kevin H.
Format Journal Article
LanguageEnglish
Published London Nature Publishing Group UK 06.02.2020
Nature Publishing Group
Subjects
639/301/1023/1026
639/301/930/12
Additive manufacturing
Characterization and analytical techniques
Contraction
Cooling
Humanities and Social Sciences
Lasers
MATERIALS SCIENCE
Metals and alloys
multidisciplinary
Science
Science (multidisciplinary)
Titanium
Titanium alloys
X-ray diffraction
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Abstract Laser powder bed fusion (LPBF) is a method of additive manufacturing characterized by the rapid scanning of a high powered laser over a thin bed of metallic powder to create a single layer, which may then be built upon to form larger structures. Much of the melting, resolidification, and subsequent cooling take place at much higher rates and with much higher thermal gradients than in traditional metallurgical processes, with much of this occurring below the surface. We have used in situ high speed X-ray diffraction to extract subsurface cooling rates following resolidification from the melt and above the β -transus in titanium alloy Ti-6Al-4V. We observe an inverse relationship with laser power and bulk cooling rates. The measured cooling rates are seen to correlate to the level of residual strain borne by the minority β -Ti phase with increased strain at slower cooling rates. The α -Ti phase shows a lattice contraction which is invariant with cooling rate. We also observe a broadening of the diffraction peaks which is greater for the β -Ti phase at slower cooling rates and a change in the relative phase fraction following LPBF. These results provide a direct measure of the subsurface thermal history and demonstrate its importance to the ultimate quality of additively manufactured materials.
AbstractList Laser powder bed fusion (LPBF) is a method of additive manufacturing characterized by the rapid scanning of a high powered laser over a thin bed of metallic powder to create a single layer, which may then be built upon to form larger structures. Much of the melting, resolidification, and subsequent cooling take place at much higher rates and with much higher thermal gradients than in traditional metallurgical processes, with much of this occurring below the surface. We have used in situ high speed X-ray diffraction to extract subsurface cooling rates following resolidification from the melt and above the β-transus in titanium alloy Ti-6Al-4V. We observe an inverse relationship with laser power and bulk cooling rates. The measured cooling rates are seen to correlate to the level of residual strain borne by the minority β-Ti phase with increased strain at slower cooling rates. The α-Ti phase shows a lattice contraction which is invariant with cooling rate. We also observe a broadening of the diffraction peaks which is greater for the β-Ti phase at slower cooling rates and a change in the relative phase fraction following LPBF. These results provide a direct measure of the subsurface thermal history and demonstrate its importance to the ultimate quality of additively manufactured materials.
Abstract Laser powder bed fusion (LPBF) is a method of additive manufacturing characterized by the rapid scanning of a high powered laser over a thin bed of metallic powder to create a single layer, which may then be built upon to form larger structures. Much of the melting, resolidification, and subsequent cooling take place at much higher rates and with much higher thermal gradients than in traditional metallurgical processes, with much of this occurring below the surface. We have used in situ high speed X-ray diffraction to extract subsurface cooling rates following resolidification from the melt and above the β -transus in titanium alloy Ti-6Al-4V. We observe an inverse relationship with laser power and bulk cooling rates. The measured cooling rates are seen to correlate to the level of residual strain borne by the minority β -Ti phase with increased strain at slower cooling rates. The α -Ti phase shows a lattice contraction which is invariant with cooling rate. We also observe a broadening of the diffraction peaks which is greater for the β -Ti phase at slower cooling rates and a change in the relative phase fraction following LPBF. These results provide a direct measure of the subsurface thermal history and demonstrate its importance to the ultimate quality of additively manufactured materials.
Laser powder bed fusion (LPBF) is a method of additive manufacturing characterized by the rapid scanning of a high powered laser over a thin bed of metallic powder to create a single layer, which may then be built upon to form larger structures. Much of the melting, resolidification, and subsequent cooling take place at much higher rates and with much higher thermal gradients than in traditional metallurgical processes, with much of this occurring below the surface. We have used in situ high speed X-ray diffraction to extract subsurface cooling rates following resolidification from the melt and above the β -transus in titanium alloy Ti-6Al-4V. We observe an inverse relationship with laser power and bulk cooling rates. The measured cooling rates are seen to correlate to the level of residual strain borne by the minority β -Ti phase with increased strain at slower cooling rates. The α -Ti phase shows a lattice contraction which is invariant with cooling rate. We also observe a broadening of the diffraction peaks which is greater for the β -Ti phase at slower cooling rates and a change in the relative phase fraction following LPBF. These results provide a direct measure of the subsurface thermal history and demonstrate its importance to the ultimate quality of additively manufactured materials.
ArticleNumber 1981
Author Toney, Michael F.
Martin, Aiden A.
Thampy, Vivek
Fong, Anthony Y.
Kiss, Andrew M.
Ott, Ryan T.
Matthews, Manyalibo J.
van Buuren, Anthony
Depond, Philip J.
Tassone, Christopher J.
Guss, Gabe
Stone, Kevin H.
Calta, Nicholas P.
Weker, Johanna Nelson
Xing, Qingfeng
Wang, Jenny
Kramer, Matthew J.
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BackLink https://www.ncbi.nlm.nih.gov/pubmed/32029753$$D View this record in MEDLINE/PubMed
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ContentType Journal Article
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CorporateAuthor SLAC National Accelerator Lab., Menlo Park, CA (United States)
Ames Laboratory (AMES), Ames, IA (United States)
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Snippet Laser powder bed fusion (LPBF) is a method of additive manufacturing characterized by the rapid scanning of a high powered laser over a thin bed of metallic...
Abstract Laser powder bed fusion (LPBF) is a method of additive manufacturing characterized by the rapid scanning of a high powered laser over a thin bed of...
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StartPage 1981
SubjectTerms 639/301/1023/1026
639/301/930/12
Additive manufacturing
Characterization and analytical techniques
Contraction
Cooling
Humanities and Social Sciences
Lasers
MATERIALS SCIENCE
Metals and alloys
multidisciplinary
Science
Science (multidisciplinary)
Titanium
Titanium alloys
X-ray diffraction
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Title Subsurface Cooling Rates and Microstructural Response during Laser Based Metal Additive Manufacturing
URI https://link.springer.com/article/10.1038/s41598-020-58598-z
https://www.ncbi.nlm.nih.gov/pubmed/32029753
https://www.proquest.com/docview/2352043822
https://search.proquest.com/docview/2352635430
https://www.osti.gov/servlets/purl/1600506
https://pubmed.ncbi.nlm.nih.gov/PMC7005153
Volume 10
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