| About this Abstract |
| Meeting |
2024 TMS Annual Meeting & Exhibition
|
| Symposium
|
Additive Manufacturing: Process-induced Microstructures and Defects
|
| Presentation Title |
Correlations of Porosity, Spatter, and Process Metrics for Powder Bed Fusion Laser Beam Metallic Additive Manufacturing |
| Author(s) |
Samuel J.A. Hocker, Andrew R. Kitahara, Brodan Richter, Sang-hyon Chu, Peter W. Spaeth, Joseph N. Zalameda, Edward H. Glaessgen |
| On-Site Speaker (Planned) |
Samuel J.A. Hocker |
| Abstract Scope |
Components fabricated using the powder bed fusion laser beam metallic additive manufacturing process are the result of a multitude of sequential weld passes and layers. Qualifying components for aerospace applications requires a thorough understanding of the process-structure property relationships. Porosity defects have an adverse effect on the mechanical properties of a component. In particular, porosity defects created by lack of fusion have high aspect ratio morphologies leading to stress concentrations that become crack initiation sites. In the present work, the occurrence of spatter induced lack of fusion porosity was studied using synchronized in-situ process monitoring, additive manufacturing model-based process metrics, and high-resolution X-ray computed tomography. Porosity is statistically correlated with unremoved welding spatter ejecta in different processing conditions that result from the same process parameters. The presentation discusses these results and how unremoved welding spatter ejecta can be modeled, predicted and controlled using process metrics related to the hatching strategy. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Computational Materials Science & Engineering, Machine Learning |