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In Situ Analysis of Laser Powder Bed Fusion Using Simultaneous High-Speed Infrared and X-ray Imaging

  • In Situ Synchrotron and Neutron Characterization of Additively Manufactured Alloys
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Abstract

Laser powder bed fusion is a metal additive manufacturing technique that has received significant scientific and industrial attention over the past decades. However, the quality and reproducibility of parts manufactured by this technique is still a problem. Overcoming this issue requires an understanding of multiple complex physical phenomena which occur simultaneously during the process. This work illustrates a powerful new technique which synchronizes high-speed x-ray imaging with high-speed infrared imaging to study laser powder bed fusion processes in real time. Using this technique, we demonstrate the simultaneous observation of multiple phenomena including three-dimensional melt pool visualization, vapor plume dynamics, spatter formation, thermal history, and point cooling rates. The paired observation of these dynamic phenomena is critical to understanding the fundamentals of laser powder bed fusion, and the overall impact of process parameters on print quality.

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Acknowledgements

The authors would like to thank Alex Deriy at the APS for their assistance in the beamline experiments. This work is partially supported by Laboratory Directed Research and Development (LDRD) funding from Argonne National Laboratory, provided by the Director, Office of Science, of the U.S. Department of Energy under Contract No. DE-AC02-06CH11357. This research used resources of the Advanced Photon Source, a U.S. Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02-06CH11357.

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Author notes

  1. Tao Sun

    Present address: Department of Materials Science and Engineering, University of Virginia, Charlottesville, VA, 22902, USA

Authors and Affiliations

  1. Interfacial Mechanics and Materials Group, Argonne National Laboratory, Lemont, IL, USA

    Benjamin Gould, Sarah Wolff, Maria Cinta Lorenzo-Martin & Aaron Greco

  2. X-ray Science Division, Argonne National Laboratory, Lemont, IL, USA

    Sarah Wolff, Niranjan Parab, Cang Zhao, Kamel Fezzaa & Tao Sun

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  1. Benjamin Gould
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  2. Sarah Wolff
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  3. Niranjan Parab
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  4. Cang Zhao
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  6. Kamel Fezzaa
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  7. Aaron Greco
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  8. Tao Sun
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Correspondence to Benjamin Gould.

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Gould, B., Wolff, S., Parab, N. et al. In Situ Analysis of Laser Powder Bed Fusion Using Simultaneous High-Speed Infrared and X-ray Imaging. JOM 73, 201–211 (2021). https://doi.org/10.1007/s11837-020-04291-5

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  • DOI: https://doi.org/10.1007/s11837-020-04291-5

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