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Meeting 2021 TMS Annual Meeting & Exhibition
Symposium Additive Manufacturing of Metals: Applications of Solidification Fundamentals
Presentation Title In Situ Imaging of the Effect of Gas Flowrates on Directed Energy Deposition
Author(s) Lorna Sinclair, Yunhui Chen, Samuel J. Clark, Oliver Hatt, Sebastian Marussi, Saurabh Shah, Robert C. Atwood, Martyn Jones, Gavin Baxter, Chu Lun Alex Leung, Iain Todd, Peter D. Lee
On-Site Speaker (Planned) Lorna Sinclair
Abstract Scope Directed Energy Deposition (DED) is a fabrication technique for rapid part production, coatings, and repair applications. However, careful selection of processing conditions is essential for obtaining the desired mechanical properties. Gas flowrates can affect the powder delivery, powder capture efficiency, and oxidation of a component. In this study, different carrier gas (powder delivery) and shielding gas (creating an inert environment around the laser) flowrates have been investigated. A unique DED process replicator has been used to observe laser deposition in situ via high-speed synchrotron radiography, revealing gas flowrate impacts on melt pool size and shape. An industrial DED machine (BeAM Magic 800) was used to build tracks under analogous processing conditions for comparison. The results showed that low gas flowrates led to thicker deposition layers and track oxidation, whereas high shield gas led to flatter, wider melt pools, and thinner deposition layers than intended.
Proceedings Inclusion? Planned:


3D Analysis of Grain Morphologies and Solidification Texture in AM 316L
3D Characterisation of Cracks Formed in AA2024 and Implications for Alloy Design
A Multi-scale Modeling Approach to Microstructure Prediction for Powder Bed Fusion Additive Manufacturing Processes Through Phase Field and Cellular Automata Methods
A Phase-field Study of Epitaxial Effect on Solidification Microstructure in Metal Additive Manufacturing
Alternative Scan Strategies for Laser Powder Bed Additive Manufacturing to Expand Process Space
Analytical Predictions and Experimental Observations of Melt Pool Geometry in Laser Powder Bed Fusion
CA Model Sensitivity to Material Parameters, Nucleation, and Thermal Conditions Across AM Process Space
Characterization of Material Solidification Behaviors in Laser Powder Bed Fusion Using Operando Synchrotron X-ray Imaging
Composition and Equilibrium Phase Diagram Feature Effects on the Printability of Alloys
Consistent Coupling between Melt Pool Heat Transfer and Grain-scale CA Calculations for Additive Manufacturing
Continuity of Eutectic Microstructures Across Melt Pool Boundaries in Laser Powder Bed Fusion
Controlling Additive Manufacturing Processes with Magnetic Fields
Creating Periodic Surface Structures Using Multiple Laser Beams
Effect of Deoxidizer Addition on Melt Pool Oxidation of AISI 316L during SLM Process
Effect of Kinetic Anisotropy on Microstructure Development during Simulated Powder Bed Fusion of 316L Stainless Steel
Energy Density on Melt Pool Dynamics and Solidification Microstructures in Laser Powder Bed Fusion Additive Manufacturing
In-situ High-speed X-ray Diffraction Study of Phase Transformation in a Laser-Processed 420 Stainless Steel
In-situ Observation of Ferritic vs Austenitic Solidification Mode Competition in 316L Laser Powder Bed Fusion Welds with Synchrotron X-ray Diffraction
In-situ X-ray Imaging of Melt Flow Dynamics in Laser Metal Additive Manufacturing
In-situ X-ray Imaging of Porosity Formation in Directed Energy Deposition
In Situ Imaging of the Effect of Gas Flowrates on Directed Energy Deposition
In situ X-ray Observation and Quantification of Keyhole-induced Porosity during Laser Additive Manufacturing
Influence of Process Parameters on the Microstructure Evolution and Mechanical Properties of Additively Manufactured 316L Stainless Steel
Influence of Processing Parameters and Geometry Effects on Residual Stress Development in Laser Powder Bed Fusion Additive Manufacturing
Influence of Scan Strategies on Surface Morphology in LPBF
Investigation into Interfacial Mixing Behavior of Blown Powder Deposited Inconel 625- Copper Alloy Bimetallic for Improvement of Bimetallic Joint Strength
Laser Powder Bed Fusion of Metal Composites via In Situ Dealloying
LPBF Processing of the Al-Ni Eutectic Alloy: Experiments and Phase Field Simulations
Melt Pool Evolution in High Power Selective Laser Melting of Nickel-based Alloy
Microstructure Control with Advanced Scan Strategies Developed via Fast Analytic Thermal Modeling of Additive Processes
Microstructure Evolution and Nanoindentation Measurements after Laser Re-solidification of Hypo-eutectic Al-10 at %Cu
Microstructure Prediction Framework for Additively Manufactured Metals
Modeling Grain Refinement for Metallic Additive Manufacturing
New Composition Based Index for Solidification Cracking Resistance
On Mesoscopic Surface Formation in Metal Laser Powder Bed Fusion Process
Optimizing and Validating the Cellular Automata Finite Element Model for Additive Manufacturing
Prediction of Columnar-to-equiaxed Transition in Single Tracks during Laser Powder Bed Fusion Additive Manufacturing
Quantification and Propagation of Aleatoric Uncertainty Through Numerical Simulation of Laser Powder Bed Fusion Process for IN625
Quantifying Impact of Fluid Flow on Melt Pool Model Predictions Across AM Processing Regimes
Quantifying the Influence of Local Layer Thickness on Pore Evolution during Laser Powder Fusion Using High-speed X-ray Imaging
Simultaneous, In-situ Synchrotron X-ray Radiography and Thermal Imaging of Liquid-to-solid Phase Transformation during Laser Fusion Processing of Ti- and Ni-alloys
Solidification Behavior of Martensitic Precipitation-hardenable Stainless Steels Produced via Additive Manufacturing
Spatial Variation of Thermokinetics and Corresponding Grain Morphology Evolution in Laser Surface Engineered IN718
Statistical Modeling of Microstructure Signatures in Laser Powder Bed Fusion
Ultrafast Dynamics of Solidification and Thermal Strain Evolution in Laser Powder Bed Additive Manufacturing Using High Energy X-ray Diffraction
Undercooling in Laser Powder Bed Fusion Metal Additive Manufacturing
Understanding Solidification of Al-Alloys Processed by Laser Powder Bed Fusion Additive Manufacturing
Using Dimensionless Numbers to Describe Process Boundaries in Laser Powder Bed Fusion
Wire Arc Additive Manufacturing of Nano-treated High Strength Aluminum Alloys

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