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In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging

Electron Beam Powder Bed Fusion (PBF-EB) is an Additive Manufacturing (AM) method that utilizes an electron beam to melt and consolidate metal powder. The beam, combined with a backscattered electron detector, enables advanced process monitoring, a method termed Electron Optical Imaging (ELO). ELO i...

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Autores principales: Gardfjell, Martin, Reith, Marcel, Franke, Martin, Körner, Carolin
Formato: Online Artículo Texto
Lenguaje:English
Publicado: MDPI 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10301515/
https://www.ncbi.nlm.nih.gov/pubmed/37374403
http://dx.doi.org/10.3390/ma16124220
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author Gardfjell, Martin
Reith, Marcel
Franke, Martin
Körner, Carolin
author_facet Gardfjell, Martin
Reith, Marcel
Franke, Martin
Körner, Carolin
author_sort Gardfjell, Martin
collection PubMed
description Electron Beam Powder Bed Fusion (PBF-EB) is an Additive Manufacturing (AM) method that utilizes an electron beam to melt and consolidate metal powder. The beam, combined with a backscattered electron detector, enables advanced process monitoring, a method termed Electron Optical Imaging (ELO). ELO is already known to provide great topographical information, but its capabilities regarding material contrast are less studied. In this article the extents of material contrast using ELO are investigated, focusing mainly on identifying powder contamination. It will be shown that an ELO detector is capable of distinguishing a single 100 μ [Formula: see text]  foreign powder particle, during an PBF-EB process, if the backscattering coefficient of the inclusion is sufficiently higher than its surroundings. Additionally, it is investigated how the material contrast can be used for material characterization. A mathematical framework is provided to describe the relationship between the signal intensity in the detector and the effective atomic number  [Formula: see text]  of the imaged alloy. The approach is verified with empirical data from twelve different materials, demonstrating that the effective atomic number of an alloy can be predicted to within one atomic number from its ELO intensity.
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spelling pubmed-103015152023-06-29 In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging Gardfjell, Martin Reith, Marcel Franke, Martin Körner, Carolin Materials (Basel) Article Electron Beam Powder Bed Fusion (PBF-EB) is an Additive Manufacturing (AM) method that utilizes an electron beam to melt and consolidate metal powder. The beam, combined with a backscattered electron detector, enables advanced process monitoring, a method termed Electron Optical Imaging (ELO). ELO is already known to provide great topographical information, but its capabilities regarding material contrast are less studied. In this article the extents of material contrast using ELO are investigated, focusing mainly on identifying powder contamination. It will be shown that an ELO detector is capable of distinguishing a single 100 μ [Formula: see text]  foreign powder particle, during an PBF-EB process, if the backscattering coefficient of the inclusion is sufficiently higher than its surroundings. Additionally, it is investigated how the material contrast can be used for material characterization. A mathematical framework is provided to describe the relationship between the signal intensity in the detector and the effective atomic number  [Formula: see text]  of the imaged alloy. The approach is verified with empirical data from twelve different materials, demonstrating that the effective atomic number of an alloy can be predicted to within one atomic number from its ELO intensity. MDPI 2023-06-07 /pmc/articles/PMC10301515/ /pubmed/37374403 http://dx.doi.org/10.3390/ma16124220 Text en © 2023 by the authors. https://creativecommons.org/licenses/by/4.0/Licensee MDPI, Basel, Switzerland. This article is an open access article distributed under the terms and conditions of the Creative Commons Attribution (CC BY) license (https://creativecommons.org/licenses/by/4.0/).
spellingShingle Article
Gardfjell, Martin
Reith, Marcel
Franke, Martin
Körner, Carolin
In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging
title In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging
title_full In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging
title_fullStr In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging
title_full_unstemmed In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging
title_short In Situ Inclusion Detection and Material Characterization in an Electron Beam Powder Bed Fusion Process Using Electron Optical Imaging
title_sort in situ inclusion detection and material characterization in an electron beam powder bed fusion process using electron optical imaging
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10301515/
https://www.ncbi.nlm.nih.gov/pubmed/37374403
http://dx.doi.org/10.3390/ma16124220
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