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In situ observation of melt pool evolution in ultrasonic vibration-assisted directed energy deposition

The presence of defects, such as pores, in materials processed using additive manufacturing represents a challenge during the manufacturing of many engineering components. Recently, ultrasonic vibration-assisted (UV-A) directed energy deposition (DED) has been shown to reduce porosity, promote grain...

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Autores principales: El-Azab, Salma A., Zhang, Cheng, Jiang, Sen, Vyatskikh, Aleksandra L., Valdevit, Lorenzo, Lavernia, Enrique J., Schoenung, Julie M.
Formato: Online Artículo Texto
Lenguaje:English
Publicado: Nature Publishing Group UK 2023
Materias:
Acceso en línea:https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10582076/
https://www.ncbi.nlm.nih.gov/pubmed/37848463
http://dx.doi.org/10.1038/s41598-023-44108-4
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author El-Azab, Salma A.
Zhang, Cheng
Jiang, Sen
Vyatskikh, Aleksandra L.
Valdevit, Lorenzo
Lavernia, Enrique J.
Schoenung, Julie M.
author_facet El-Azab, Salma A.
Zhang, Cheng
Jiang, Sen
Vyatskikh, Aleksandra L.
Valdevit, Lorenzo
Lavernia, Enrique J.
Schoenung, Julie M.
author_sort El-Azab, Salma A.
collection PubMed
description The presence of defects, such as pores, in materials processed using additive manufacturing represents a challenge during the manufacturing of many engineering components. Recently, ultrasonic vibration-assisted (UV-A) directed energy deposition (DED) has been shown to reduce porosity, promote grain refinement, and enhance mechanical performance in metal components. Whereas it is evident that the formation of such microstructural features is affected by the melt pool behavior, the specific mechanisms by which ultrasonic vibration (UV) influences the melt pool remain elusive. In the present investigation, UV was applied in situ to DED of 316L stainless steel single tracks and bulk parts. For the first time, high-speed video imaging and thermal imaging were implemented in situ to quantitatively correlate the application of UV to melt pool evolution in DED. Extensive imaging data were coupled with in-depth microstructural characterization to develop a statistically robust dataset describing the observed phenomena. Our findings show that UV increases the melt pool peak temperature and dimensions, while improving the wettability of injected particles with the melt pool surface and reducing particle residence time. Near the substrate, we observe that UV results in a 92% decrease in porosity, and a 54% decrease in dendritic arm spacing. The effect of UV on the melt pool is caused by the combined mechanisms of acoustic cavitation, ultrasound absorption, and acoustic streaming. Through in situ imaging we demonstrate quantitatively that these phenomena, acting simultaneously, effectively diminish with increasing build height and size due to acoustic attenuation, consequently decreasing the positive effect of implementing UV-A DED. Thus, this research provides valuable insight into the value of in situ imaging, as well as the effects of UV on DED melt pool dynamics, the stochastic interactions between the melt pool and incoming powder particles, and the limitations of build geometry on the UV-A DED technique.
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spelling pubmed-105820762023-10-19 In situ observation of melt pool evolution in ultrasonic vibration-assisted directed energy deposition El-Azab, Salma A. Zhang, Cheng Jiang, Sen Vyatskikh, Aleksandra L. Valdevit, Lorenzo Lavernia, Enrique J. Schoenung, Julie M. Sci Rep Article The presence of defects, such as pores, in materials processed using additive manufacturing represents a challenge during the manufacturing of many engineering components. Recently, ultrasonic vibration-assisted (UV-A) directed energy deposition (DED) has been shown to reduce porosity, promote grain refinement, and enhance mechanical performance in metal components. Whereas it is evident that the formation of such microstructural features is affected by the melt pool behavior, the specific mechanisms by which ultrasonic vibration (UV) influences the melt pool remain elusive. In the present investigation, UV was applied in situ to DED of 316L stainless steel single tracks and bulk parts. For the first time, high-speed video imaging and thermal imaging were implemented in situ to quantitatively correlate the application of UV to melt pool evolution in DED. Extensive imaging data were coupled with in-depth microstructural characterization to develop a statistically robust dataset describing the observed phenomena. Our findings show that UV increases the melt pool peak temperature and dimensions, while improving the wettability of injected particles with the melt pool surface and reducing particle residence time. Near the substrate, we observe that UV results in a 92% decrease in porosity, and a 54% decrease in dendritic arm spacing. The effect of UV on the melt pool is caused by the combined mechanisms of acoustic cavitation, ultrasound absorption, and acoustic streaming. Through in situ imaging we demonstrate quantitatively that these phenomena, acting simultaneously, effectively diminish with increasing build height and size due to acoustic attenuation, consequently decreasing the positive effect of implementing UV-A DED. Thus, this research provides valuable insight into the value of in situ imaging, as well as the effects of UV on DED melt pool dynamics, the stochastic interactions between the melt pool and incoming powder particles, and the limitations of build geometry on the UV-A DED technique. Nature Publishing Group UK 2023-10-17 /pmc/articles/PMC10582076/ /pubmed/37848463 http://dx.doi.org/10.1038/s41598-023-44108-4 Text en © The Author(s) 2023 https://creativecommons.org/licenses/by/4.0/Open Access This article is licensed under a Creative Commons Attribution 4.0 International License, which permits use, sharing, adaptation, distribution and reproduction in any medium or format, as long as you give appropriate credit to the original author(s) and the source, provide a link to the Creative Commons licence, and indicate if changes were made. The images or other third party material in this article are included in the article's Creative Commons licence, unless indicated otherwise in a credit line to the material. If material is not included in the article's Creative Commons licence and your intended use is not permitted by statutory regulation or exceeds the permitted use, you will need to obtain permission directly from the copyright holder. To view a copy of this licence, visit http://creativecommons.org/licenses/by/4.0/ (https://creativecommons.org/licenses/by/4.0/) .
spellingShingle Article
El-Azab, Salma A.
Zhang, Cheng
Jiang, Sen
Vyatskikh, Aleksandra L.
Valdevit, Lorenzo
Lavernia, Enrique J.
Schoenung, Julie M.
In situ observation of melt pool evolution in ultrasonic vibration-assisted directed energy deposition
title In situ observation of melt pool evolution in ultrasonic vibration-assisted directed energy deposition
title_full In situ observation of melt pool evolution in ultrasonic vibration-assisted directed energy deposition
title_fullStr In situ observation of melt pool evolution in ultrasonic vibration-assisted directed energy deposition
title_full_unstemmed In situ observation of melt pool evolution in ultrasonic vibration-assisted directed energy deposition
title_short In situ observation of melt pool evolution in ultrasonic vibration-assisted directed energy deposition
title_sort in situ observation of melt pool evolution in ultrasonic vibration-assisted directed energy deposition
topic Article
url https://www.ncbi.nlm.nih.gov/pmc/articles/PMC10582076/
https://www.ncbi.nlm.nih.gov/pubmed/37848463
http://dx.doi.org/10.1038/s41598-023-44108-4
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