Experimental study of single tracks obtained from a mixture of Ti and Al powders with varying selective laser melting parameters

Abstract

The paper studies the effect of the laser scanning speed (vs) on the morphology of single tracks obtained from a mixture of Ti and Al powders in a stoichiometric ratio of 1 : 1 in longitudinal and cross sections. Droplets of splashed liquid were found on the outer surface of the track obtained at vs = 300 mm/s. Their appearance is resulted most likely from the release of gas bubbles formed due to the evaporation of aluminum having a lower melting point. A distortion of a single track along its length was observed with an increase in vs values up to 600 mm/s. It was found that tracks loose stability as the laser beam speed increases with «balls» formed on the track surface due to the significant Marangoni convection and the capillary liquid instability in the molten bath. An increase in the laser speed led to the appearance of pores mainly concentrated in the formed balls, and also influenced the track morphology in the cross section, namely, the width and height of the track, as well as the depth of substrate fusion. An increase in the scanning speed from 300 to 900 mm/s led virtually no substrate fusion, and the track width decreased from 194 to 136 μm, while its height increased almost 4 times – from 21 to 88 μm. X-ray microanalysis was conducted and element distribution maps were obtained to assess the structure of the tracks under study. It was found that the degree of liquid mixing in the molten bath is insufficient at scanning speeds of 300 and 600 mm/s, which leads to the segregation of elements over the track cross section. The central zone turns out to be enriched in aluminum, while titanium predominates at the base and is practically absent in the extreme zone (4.57 at.% Ti). X-ray microanalysis revealed the presence of unmelted titanium powder particles at vs = 900 mm/s. Presumably, it may be caused by insufficient laser power at such a high scanning speed.