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Meeting 2018 TMS Annual Meeting & Exhibition
Symposium Application of Solidification Fundamentals to Challenges in Metal Additive Manufacturing
Presentation Title Fast Synchrotron X-ray Imaging of the Mechanisms Controlling Laser Additive Manufacturing
Author(s) Peter D. Lee, Chu Lun Alex Leung, Enyu Guo, Sebastian Marussi, Robert Atwood, Mike Towrie, Phil J Withers
On-Site Speaker (Planned) Peter D. Lee
Abstract Scope Laser powder bed additive manufacturing (LAM) promises to produce unique, high quality components for aerospace to biomedical applications. However, the mechanisms controlling the formation of continuous, defect free, track are still poorly understood. The cooling rates are far from equilibrium causing solidification defects (porosity, epitaxial growth) and high residual stresses. We present a step change in the methodology used to characterise and optimise the process using fast synchrotron X-ray imaging and a bespoke LAM process replicator (LAMPR). We apply the LAMPR over a range of laser velocities and powers, developing a mechanism map to predicting the processing conditions when LAM is effective for a given material. Further, we capture the mechanisms by which LAM fails, providing unprecedented insight into what controls additive manufacturing’s process window, and how to extend it. This revelation allows dynamic evolution of melt features, including track morphology (continuous to balling), pore formation and spatter.
Proceedings Inclusion? Planned: Supplemental Proceedings volume


Application of Interface Response Function Theory to Describe Non-equilibrium Solidification during Welding and Additive Manufacturing
Building Microstructure-cooling Rate Relationships in Laser Welded Uranium-6 Wt. Pct. Niobium for Laser Powder Bed Fusion Processing
Cellular Automata Modeling of Nucleation and Grain Growth in Alloy-based Additive Manufacturing
Characterization of Rapid Cooling during Laser Powder Bed Fusion Additive Manufacturing of Ti-6Al-4V Using In Situ High Speed Synchrotron X-ray Diffraction
Crystal Growth in Face-centred-cubic Alloys Made by Additive Manufacturing: Epitaxial Growth, Branching and Splitting
Development of an In-situ TEM with Laser Sintering Capabilities at Sandia National Laboratories
Dynamics of Melting and Resolidification: Application to the Inter-layer Band Microstructure in Laser Metal Deposition
Enabling New Additive Alloys through Solidification Control
Experimental and Simulation Study of Solidification and Micro-structural Evolution of Liquid Metal Alloys for Additive Manufacturing Process Simulation and Materials Design
Fast Synchrotron X-ray Imaging of the Mechanisms Controlling Laser Additive Manufacturing
Fluid Dynamics Effects on Microstructure Prediction in the Laser Additive Manufacturing Process
Heat Transfer and Fluid Flow during Fabrication of Overhang Structure in Laser-powder Bed Fusion Additive Manufacturing
In-situ Monitoring of Solidification during Powder-deposition Based Additive Manufacturing
Laser Powder Bed Fusion of Metal and Bioactive Glass Revealed Via Synchrotron X-ray Imaging
Microstructural Modeling of the Solidification of Alloys in Additive Manufacture
Microstructure and Wear Resistance of Laser Deposited Cobalt-free Cu-based Alloy for Valve Seat Application
Microstructure Control in Laser Powder Bed Fusion: Correlating Directional Solidification Parameters with Selected Process Variables and Material’s Properties
Microstructure Formation in Rapid Solidification of Electron-beam Melted Ni-Sn Alloys
Phase-field Modeling of Solidification Microstructures during Additive Manufacturing
Phase-field Modeling of Solidification under SLM Conditions
Simulating Grain Formation during Metal Additive Manufacturing (AM): Potential Pathways for Producing Equiaxed Grain Structures
Solid Solubility Extension and Microstructural Evolution during Single and Double Pass Laser Scans in Al-Co and Al-Ce Binary Alloys
Solidification Cracking during Selective Laser Melting (SLM) of Nickel-base Superalloy Inconel-738LC
The Effect of Grain Refiners on the Columnar to Equiaxed Transition in Metal Additive Manufacturing of Aluminium Alloys
Tomography and 3D Grain Mapping for Additive Manufacturing Qualification

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