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In-situ Observations of Directed Energy Deposition Additive Manufacturing Using High-Speed X-ray Imaging

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

In laser-based directed energy deposition (DED) additive manufacturing, interactions among the laser beam, particle flow, and melt pool influence the properties of the solidified final part. Two separate DED systems, one with high powder flow rates to represent industrial-scale DED processing and the other with low powder flow rates for individual particle tracking, were synchronized with the high-speed imaging setup at the Advanced Photon Source in Argonne National Laboratory. In-situ x-ray imaging of the DED process using both systems highlighted the influence of powder flow rates. Increased powder flow rates resulted in less laser absorption into the melt pool, leading to a transition from a keyhole mode to a melt pool without a keyhole but with surface fluctuations due to powder flow. Increased velocities of particles during powder flow resulted in a decrease in particle melting times and a greater propensity for porosity formation. Overall, better understanding of the interactions that occur during various scales of the DED process will enable flexibility, control, and new materials development in DED-based additive manufacturing.

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Acknowledgements

The authors acknowledge the following: Yi Shi, Nicolas Martinez, Suman Bhandari, and Jennifer Bennett for experiment execution and Kamel Fezzaa and Alex Deriy at the beamline. The authors also acknowledge Profs. Kornel Ehmann and Jian Cao from Northwestern University for acquiring funding and their guidance on the work. This research used resources of the Advanced Photon Source, a US Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory (ANL) under contract no. DE-AC02-06CH11357 in addition to support through Laboratory Directed Research and Development (LDRD) funding from ANL under the same contract. This research was also funded by the Northwestern Initiative for Manufacturing Science and Innovation (NIMSI) and the US Department of Commence National Institute of Standards and Technology’s Center for Hierarchical Materials Design (CHiMaD) under grant no. 70NANB14H012. This material is based upon work supported by the National Science Foundation Graduate Research Fellowship under grant no. DGE-1842165.

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Author notes

  1. Sarah J. Wolff and Samantha Webster have contributed equally to this work.

Authors and Affiliations

  1. Industrial and Systems Engineering, Texas A&M University, College Station, TX, 77843, USA

    Sarah J. Wolff

  2. Mechanical Engineering, Northwestern University, Evanston, IL, 60208, USA

    Samantha Webster

  3. X-ray Science Division, Argonne National Laboratory, Lemont, IL, 60439, USA

    Niranjan D. Parab

  4. Applied Materials Division, Argonne National Laboratory, Lemont, IL, 60439, USA

    Benjamin Aronson, Benjamin Gould & Aaron Greco

  5. Department of Materials Science and Engineering, University of Virginia, Charlottesville, VA, 22902, USA

    Tao Sun

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  1. Sarah J. Wolff
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Correspondence to Sarah J. Wolff.

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Wolff, S.J., Webster, S., Parab, N.D. et al. In-situ Observations of Directed Energy Deposition Additive Manufacturing Using High-Speed X-ray Imaging. JOM 73, 189–200 (2021). https://doi.org/10.1007/s11837-020-04469-x

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  • DOI: https://doi.org/10.1007/s11837-020-04469-x

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