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Meeting 2024 TMS Annual Meeting & Exhibition
Symposium Novel Strategies for Rapid Acquisition and Processing of Large Datasets from Advanced Characterization Techniques
Presentation Title Melt Pool Quantification from In Situ Radiography of Directed Energy Deposition of Nickel Superalloys
Author(s) Imogen Cowley, Kai Zhang, Sebastian Marussi, Shishira Bhagavath, Harry Chapman, Chu Lun Alex Leung, Robert Atwood, Martyn A. Jones, Peter D. Lee
On-Site Speaker (Planned) Imogen Cowley
Abstract Scope In situ synchrotron radiography is a fast growing area of metal additive manufacturing research. We reveal the dynamic process physics using high energy x-ray imaging, including melt pool behaviour, keyhole behaviour, formation of pores, and cracking. However, the melt pool can be challenging to identify in x-ray images, with little contrast between liquid and solid phases. Image processing procedures are required to reveal the melt pool boundary and enable quantification of characteristics like depth and dilution for large datasets. Here, in situ and operando synchrotron radiography (DLS I-12, beamtimes MG30735 & MG31855) is used to study blown-powder DED of RR1000, a nickel superalloy used in turbine disk applications, and produce a process map. Melt pool characteristics are quantified across a range of laser powers, laser scan speeds, powder feed rates, and laser spot sizes. Image processing approaches for automated identification and quantification of the melt pool are presented.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Characterization, Other


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