| About this Abstract |
| Meeting |
2022 TMS Annual Meeting & Exhibition
|
| Symposium
|
Defects and Properties of Cast Metals IV
|
| Presentation Title |
Quantifying Pore Evolution during Laser Powder Fusion Using High-speed X-ray Imaging and High Fidelity Multiphase Simulation |
| Author(s) |
Chu Lun Alex Leung, Michael Mallon, Dawid Luczyniec, Yuze Huang, Samuel J. Clark, Yunhui Chen, Sebastian Marussi, Lorna Sinclair, Margie P. Olbinado, Elodie Boller, Alexander Rack, Iain Todd, Peter D. Lee |
| On-Site Speaker (Planned) |
Chu Lun Alex Leung |
| Abstract Scope |
Laser powder bed fusion additive manufacturing (LPBF) produces complex net-shape parts from alloy powders, in a layer-by-layer manner. X-ray imaging studies of pore evolution mostly focus on single-layer tracks on substrates, missing the interaction of the laser beam with pre-existing pores in prior layers. Here, we used an in situ and operando process replicator (ISOPR), synchrotron X-ray imaging and high fidelity simulation to monitor and elucidate the process dynamics during a multilayer build of a Ni-superalloy. We quantify the changes in keyhole geometry, porosity, and remelting zone, as a function of time, layer number, and local layer thickness. These results were compared with a multiphase and multiphysics simulation to reveal the solid-liquid-gas-metal vapour interaction, keyhole evolution mechanisms, melt pool, and porosity. This work highlights the impact of layer thickness on build quality for powder bed fusion processes and suggests ways to mitigate the formation of imperfections. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Solidification, Modeling and Simulation |