Additive Manufacturing Benchmarks 2022 (AM-Bench 2022): Thursday Plenary & Benchmarks
Program Organizers: Brandon Lane, National Institute of Standards and Technology; Lyle Levine, National Institute of Standards and Technology
Thursday 8:30 AM
August 18, 2022
Room: Regency Ballroom I & II
Location: Hyatt Regency Bethesda
Session Chair: Nikolas Hrabe, National Institute of Standards and Technology - Boulder
8:30 AM Plenary
Material Property Control in Directed Energy Deposition: Jian Cao1; 1Northwestern University
We aim to understand how porosities in the metal directed energy deposition (DED) process are formed, to achieve desired material property by using simulation-guided process design, and to counter machine-to-machine variations by fusing simulation and experimental data. High-speed synchrotron imaging has been used for in-situ observation of melt-pool dynamics, powder entrainment, and defect formation in laser powder bed fusion (LPBF), but phenomena in powder-blown processes, such as directed energy deposition (DED), will be very different due to much more stochastic and violent powder delivery. Our group addresses those differences by using the X-ray imaging technique at the Advanced Photon Source and a high through-put DED set-up to measure melt-pool geometry and fluctuations over a large range of energy densities and mass flowrates. Melt-pool conditions leading to pore formation and pore entrapment are elucidated and will be discussed. Finally, process control of the DED process at the macro-scale will be presented.
9:00 AM Plenary
In-situ Characterization of Melt Pool Dynamics by High-speed Synchrotron X-ray Imaging and Diffraction: Lianyi Chen1; 1University of Wisconsin-Madison
High-speed synchrotron x-ray imaging and diffraction are powerful tools for characterizing melt pool dynamics (especially beneath the surface of the melt pool) during laser powder bed fusion additive manufacturing process. In this talk, I will present the key data and insights my research group obtained on (1) melt pool fluctuation/instabilities (including both geometry of the melt pool and melt flow within the melt pool), (2) defects formation and evolution, and (3) solidification dynamics. At the end, I will briefly introduce the defects mitigation approaches we developed based on the new mechanisms we discovered and the new insights we obtained from the in-situ characterization study.
9:30 AM Plenary
Experimental Data for the Asynchronous AM Bench Challenge: Coupling Laser Absorption with High-speed X-ray Imaging: Brian Simonds1; Jack Tanner2; Paul Williams; Niranjan Parab3; Tao Sun2; 1National Institute of Standards and Technology; 2TBD; 3Argonne National Laboratory
The absorbed laser light provides all of the energy driving laser powder bed fusion additive manufacturing (AM) phenomenon – from melting to solidification. As such, it is a vital parameter for accurate predictions of AM processes. The first Asynchronous AM Benchmark (A-AMBench) challenge was designed to test the ability of simulations to accurately predict laser power absorption as well as various melt pool behaviors (width, depth, and solidification) during laser melt melting of solid aluminum during stationary and scanned laser illumination. The experimental data, against which challenge submission are judged, were obtained during a series of experiments at the Advanced Photon Source at Argonne National Laboratories combining integrating sphere radiometry and high-speed X-ray imaging. In this talk, we will present these experimental data and discuss how they were used with respect to the A-AMBench challenge.
10:00 AM Question and Answer Period
10:10 AM Break