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The interplay between vapour, liquid, and solid phases in laser powder bed fusion
The capability of producing complex, high performance metal parts on demand has established laser powder bed fusion (LPBF) as a promising additive manufacturing technology, yet deeper understanding of the laser-material interaction is crucial to exploit the potential of the process. By simultaneous...
Autores principales: | , , , , , |
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Formato: | Online Artículo Texto |
Lenguaje: | English |
Publicado: |
Nature Publishing Group UK
2022
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Materias: | |
Acceso en línea: | https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9135709/ https://www.ncbi.nlm.nih.gov/pubmed/35618737 http://dx.doi.org/10.1038/s41467-022-30667-z |
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author | Bitharas, I. Parab, N. Zhao, C. Sun, T. Rollett, A. D. Moore, A. J. |
author_facet | Bitharas, I. Parab, N. Zhao, C. Sun, T. Rollett, A. D. Moore, A. J. |
author_sort | Bitharas, I. |
collection | PubMed |
description | The capability of producing complex, high performance metal parts on demand has established laser powder bed fusion (LPBF) as a promising additive manufacturing technology, yet deeper understanding of the laser-material interaction is crucial to exploit the potential of the process. By simultaneous in-situ synchrotron x-ray and schlieren imaging, we probe directly the interconnected fluid dynamics of the vapour jet formed by the laser and the depression it produces in the melt pool. The combined imaging shows the formation of a stable plume over stable surface depressions, which becomes chaotic following transition to a full keyhole. We quantify process instability across several parameter sets by analysing keyhole and plume morphologies, and identify a previously unreported threshold of the energy input required for stable line scans. The effect of the powder layer and its impact on process stability is explored. These high-speed visualisations of the fluid mechanics governing LPBF enable us to identify unfavourable process dynamics associated with unwanted porosity, aiding the design of process windows at higher power and speed, and providing the potential for in-process monitoring of process stability. |
format | Online Article Text |
id | pubmed-9135709 |
institution | National Center for Biotechnology Information |
language | English |
publishDate | 2022 |
publisher | Nature Publishing Group UK |
record_format | MEDLINE/PubMed |
spelling | pubmed-91357092022-05-28 The interplay between vapour, liquid, and solid phases in laser powder bed fusion Bitharas, I. Parab, N. Zhao, C. Sun, T. Rollett, A. D. Moore, A. J. Nat Commun Article The capability of producing complex, high performance metal parts on demand has established laser powder bed fusion (LPBF) as a promising additive manufacturing technology, yet deeper understanding of the laser-material interaction is crucial to exploit the potential of the process. By simultaneous in-situ synchrotron x-ray and schlieren imaging, we probe directly the interconnected fluid dynamics of the vapour jet formed by the laser and the depression it produces in the melt pool. The combined imaging shows the formation of a stable plume over stable surface depressions, which becomes chaotic following transition to a full keyhole. We quantify process instability across several parameter sets by analysing keyhole and plume morphologies, and identify a previously unreported threshold of the energy input required for stable line scans. The effect of the powder layer and its impact on process stability is explored. These high-speed visualisations of the fluid mechanics governing LPBF enable us to identify unfavourable process dynamics associated with unwanted porosity, aiding the design of process windows at higher power and speed, and providing the potential for in-process monitoring of process stability. Nature Publishing Group UK 2022-05-26 /pmc/articles/PMC9135709/ /pubmed/35618737 http://dx.doi.org/10.1038/s41467-022-30667-z Text en © The Author(s) 2022 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 license, and indicate if changes were made. The images or other third party material in this article are included in the article’s Creative Commons license, unless indicated otherwise in a credit line to the material. If material is not included in the article’s Creative Commons license 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 license, visit http://creativecommons.org/licenses/by/4.0/ (https://creativecommons.org/licenses/by/4.0/) . |
spellingShingle | Article Bitharas, I. Parab, N. Zhao, C. Sun, T. Rollett, A. D. Moore, A. J. The interplay between vapour, liquid, and solid phases in laser powder bed fusion |
title | The interplay between vapour, liquid, and solid phases in laser powder bed fusion |
title_full | The interplay between vapour, liquid, and solid phases in laser powder bed fusion |
title_fullStr | The interplay between vapour, liquid, and solid phases in laser powder bed fusion |
title_full_unstemmed | The interplay between vapour, liquid, and solid phases in laser powder bed fusion |
title_short | The interplay between vapour, liquid, and solid phases in laser powder bed fusion |
title_sort | interplay between vapour, liquid, and solid phases in laser powder bed fusion |
topic | Article |
url | https://www.ncbi.nlm.nih.gov/pmc/articles/PMC9135709/ https://www.ncbi.nlm.nih.gov/pubmed/35618737 http://dx.doi.org/10.1038/s41467-022-30667-z |
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