| About this Abstract |
| Meeting |
2023 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2023)
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| Symposium
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2023 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2023)
|
| Presentation Title |
Assessing the Impact of Melt Pool Variability on Fatigue Life in Laser Powder Bed Fusion |
| Author(s) |
Justin Patrick Miner, Tharun Reddy, Austin Ngo, Christian Gobert, Jack Beuth, Anthony Rollett, John Lewandowski, Sneha Prahba Narra |
| On-Site Speaker (Planned) |
Justin Patrick Miner |
| Abstract Scope |
Stress intensities created by sharp, lack-of-fusion (LOF) defects, hinder fatigue life of laser powder bed fusion components. LOF defects result from insufficient melt pool overlap which depends on process parameters, layer thickness and hatch spacing. The delineation between parameters producing parts with and without LOF defects is the LOF boundary. However, recent studies hypothesize that infrequent LOF defects can occur outside of the LOF region through melt pool instabilities. To evaluate this problem, this work utilizes spectral analysis of single and multi-tracks and computed tomography of the bulk samples to evaluate the geometric variability of melt tracks produced within the process window as determined by melt pool geometry-based LOF modeling. The results suggest that melt pool variation generates LOF defects within the process window near the LOF boundary. Because of the impact of LOF pores on fatigue life, a conservative process window accounting for melt pool geometric variation is needed. |
| Proceedings Inclusion? |
Definite: Post-meeting proceedings |