Da Guo, Rubén Lambert-Garcia, Samy Hocine, Xianqiang Fan, Henry Greenhalgh, ravi shahani, Marta Majkut, A. Rack, Peter D. Lee, C. L. Leung
{"title":"Al-Fe-Zr 合金激光粉末床熔融过程中的相关喷溅和蒸汽郁积动力学","authors":"Da Guo, Rubén Lambert-Garcia, Samy Hocine, Xianqiang Fan, Henry Greenhalgh, ravi shahani, Marta Majkut, A. Rack, Peter D. Lee, C. L. Leung","doi":"10.1088/2631-7990/ad4e1d","DOIUrl":null,"url":null,"abstract":"\n Spatter during laser powder bed fusion (LPBF) can induce surface defects, impacting the fatigue performance of the fabricated components. Here, we reveal and explain the links between vapour depression shape and spatter dynamics during LPBF of an Al-Fe-Zr aluminium alloy using high-speed synchrotron X-ray imaging. We quantify the number, trajectory angle, velocity, and kinetic energy of the spatter as a function of vapour depression zone/keyhole morphology under industry-relevant processing conditions. The depression zone/keyhole morphology was found to influence the spatter ejection angle in keyhole versus conduction melting modes: (i) the vapour-pressure driven plume in conduction mode with a quasi-semi-circular depression zone leads to backward spatter whereas (ii) the keyhole rear wall redirects the gas/vapour flow to cause vertical spatter ejection and rear rim droplet spatter. Increasing the opening of the keyhole or vapour depression zone can reduce entrainment of solid spatter. We discover a spatter-induced crater mechanism in which small spatter particles are accelerated towards the powder bed after laser-spatter interaction, inducing powder denudation and cavities on the printed surface. By quantifying these laser-spatter interactions, we suggest a printing strategy for minimising defects and improving the surface quality of LPBF parts.","PeriodicalId":52353,"journal":{"name":"International Journal of Extreme Manufacturing","volume":null,"pages":null},"PeriodicalIF":16.1000,"publicationDate":"2024-05-20","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":"{\"title\":\"Correlative spatter and vapour depression dynamics during laser powder bed fusion of an Al-Fe-Zr alloy\",\"authors\":\"Da Guo, Rubén Lambert-Garcia, Samy Hocine, Xianqiang Fan, Henry Greenhalgh, ravi shahani, Marta Majkut, A. Rack, Peter D. Lee, C. L. Leung\",\"doi\":\"10.1088/2631-7990/ad4e1d\",\"DOIUrl\":null,\"url\":null,\"abstract\":\"\\n Spatter during laser powder bed fusion (LPBF) can induce surface defects, impacting the fatigue performance of the fabricated components. Here, we reveal and explain the links between vapour depression shape and spatter dynamics during LPBF of an Al-Fe-Zr aluminium alloy using high-speed synchrotron X-ray imaging. We quantify the number, trajectory angle, velocity, and kinetic energy of the spatter as a function of vapour depression zone/keyhole morphology under industry-relevant processing conditions. The depression zone/keyhole morphology was found to influence the spatter ejection angle in keyhole versus conduction melting modes: (i) the vapour-pressure driven plume in conduction mode with a quasi-semi-circular depression zone leads to backward spatter whereas (ii) the keyhole rear wall redirects the gas/vapour flow to cause vertical spatter ejection and rear rim droplet spatter. Increasing the opening of the keyhole or vapour depression zone can reduce entrainment of solid spatter. We discover a spatter-induced crater mechanism in which small spatter particles are accelerated towards the powder bed after laser-spatter interaction, inducing powder denudation and cavities on the printed surface. By quantifying these laser-spatter interactions, we suggest a printing strategy for minimising defects and improving the surface quality of LPBF parts.\",\"PeriodicalId\":52353,\"journal\":{\"name\":\"International Journal of Extreme Manufacturing\",\"volume\":null,\"pages\":null},\"PeriodicalIF\":16.1000,\"publicationDate\":\"2024-05-20\",\"publicationTypes\":\"Journal Article\",\"fieldsOfStudy\":null,\"isOpenAccess\":false,\"openAccessPdf\":\"\",\"citationCount\":\"0\",\"resultStr\":null,\"platform\":\"Semanticscholar\",\"paperid\":null,\"PeriodicalName\":\"International Journal of Extreme Manufacturing\",\"FirstCategoryId\":\"5\",\"ListUrlMain\":\"https://doi.org/10.1088/2631-7990/ad4e1d\",\"RegionNum\":1,\"RegionCategory\":\"工程技术\",\"ArticlePicture\":[],\"TitleCN\":null,\"AbstractTextCN\":null,\"PMCID\":null,\"EPubDate\":\"\",\"PubModel\":\"\",\"JCR\":\"Q1\",\"JCRName\":\"ENGINEERING, MANUFACTURING\",\"Score\":null,\"Total\":0}","platform":"Semanticscholar","paperid":null,"PeriodicalName":"International Journal of Extreme Manufacturing","FirstCategoryId":"5","ListUrlMain":"https://doi.org/10.1088/2631-7990/ad4e1d","RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
Correlative spatter and vapour depression dynamics during laser powder bed fusion of an Al-Fe-Zr alloy
Spatter during laser powder bed fusion (LPBF) can induce surface defects, impacting the fatigue performance of the fabricated components. Here, we reveal and explain the links between vapour depression shape and spatter dynamics during LPBF of an Al-Fe-Zr aluminium alloy using high-speed synchrotron X-ray imaging. We quantify the number, trajectory angle, velocity, and kinetic energy of the spatter as a function of vapour depression zone/keyhole morphology under industry-relevant processing conditions. The depression zone/keyhole morphology was found to influence the spatter ejection angle in keyhole versus conduction melting modes: (i) the vapour-pressure driven plume in conduction mode with a quasi-semi-circular depression zone leads to backward spatter whereas (ii) the keyhole rear wall redirects the gas/vapour flow to cause vertical spatter ejection and rear rim droplet spatter. Increasing the opening of the keyhole or vapour depression zone can reduce entrainment of solid spatter. We discover a spatter-induced crater mechanism in which small spatter particles are accelerated towards the powder bed after laser-spatter interaction, inducing powder denudation and cavities on the printed surface. By quantifying these laser-spatter interactions, we suggest a printing strategy for minimising defects and improving the surface quality of LPBF parts.
期刊介绍:
The International Journal of Extreme Manufacturing (IJEM) focuses on publishing original articles and reviews related to the science and technology of manufacturing functional devices and systems with extreme dimensions and/or extreme functionalities. The journal covers a wide range of topics, from fundamental science to cutting-edge technologies that push the boundaries of currently known theories, methods, scales, environments, and performance. Extreme manufacturing encompasses various aspects such as manufacturing with extremely high energy density, ultrahigh precision, extremely small spatial and temporal scales, extremely intensive fields, and giant systems with extreme complexity and several factors. It encompasses multiple disciplines, including machinery, materials, optics, physics, chemistry, mechanics, and mathematics. The journal is interested in theories, processes, metrology, characterization, equipment, conditions, and system integration in extreme manufacturing. Additionally, it covers materials, structures, and devices with extreme functionalities.