Metal Laser Powder Bed Fusion Research Articles

Mechanical response and failure modes of three-dimensional auxetic re-entrant LPBF-manufactured steel truss lattice materials

Abstract Auxetic architected materials present a novel class of damage-tolerant materials with tunable mechanical characteristics and high energy absorption due to their unique ability to laterally contract and densify when subjected to axial compressive loading. The current state of research on negative Poisson's ratio materials mainly focuses on 2D geometries and a few families of 3D geometries with limited experimental comparisons between different architectures and various geometrical features. Furthermore, when manufactured via laser powder bed fusion, the influence of as-built deviations of geometrical and material properties inherently present due to the melt pool solidification process for thin features is relatively unexplored in the case of metal architected materials. The authors aim to study the elastic properties, peak characteristics, and failure modes of steel auxetic truss lattices subjected to axial compression while also addressing the uncertainties inherent to the metal laser powder bed fusion additive manufacturing of architected materials. This work presents an experimental and computational exploration and comparison of two promising three-dimensional auxetic truss lattice families of low relative densities. A comprehensive investigation of metal negative Poisson's ratio mechanical metamaterials is presented, including the selection of the architectures, modeling, laser powder bed fusion additive manufacturing, as-built part characterization, material testing, and mechanical testing under axial compression. The study of such architectures can unlock their potential in making them readily adaptable to a wide variety of engineering applications.

An Interactive Web-Based Platform for Support Generation and Optimisation for Metal Laser Powder Bed Fusion.

Powder bed fusion-laser beam (PBF-LB), a prevalent and rapidly advancing additive manufacturing (AM) technology nowadays, serves the industry by producing thin, complex, and lightweight components for various sectors, including healthcare, automotive, defence, and aerospace. However, this technology encounters challenges related to the construction of critical parts and the high overall process costs. Equally significant is the role of support structures in metal laser powder bed fusion (PBF-LB/M). The absence of supports can lead to defective and collapsed parts, while the incorrect selection of a support type or the addition of unnecessary supports results in increased material usage and additional post-processing efforts. Therefore, there is a pressing need for advanced software capable of generating appropriate support structures and predicting the thermomechanical behaviour of a part under PBF-LB/M printing conditions. Such software would be beneficial for the industry to avoid printing defects caused by high thermal stresses, minimise material usage, reduce printing time, and ensure high-quality prints. In this study, we introduce a web-based support generation and optimisation platform for PBF-LB/M. Through this platform, among other features, users can import three-dimensional (3D) parts and generate block-type support structures with diamond perforations based on the PySLM library, all within a user-friendly web environment. The first release of the platform (v0.6) is fully interactive and accessible online at no cost.

Material dependent influence of ring/spot beam profiles in laser powder bed fusion

In recent years, the topic of beam shaping for improved laser material processing has rapidly grown influencing metal laser powder bed fusion (PBF-LB/M). Given the need to reduce the cost and improve control of the PBF-LB/M process to make it more competitive with traditional manufacturing methods, increasing productivity of PBF-LB/M is critical. When research reports a new beam profile (e.g. ring profile) to improve productivity on a specific material, it is often generalised, and assumed to have the capability to improve productivity in PBF-LB/M across the board. In this work, we use both low-fidelity simulations and experimental work to investigate the difference between Gaussian and ring/spot beam profiles on metals with very different thermal properties (a stainless steel and an aluminium alloy). We show that the two materials have opposite responses to the change in beam profile (both in terms of melt pool dimensions and thermal gradients); further, the most beneficial intensity distribution is dependent on the energy input to the material. This exemplifies yet another way in which the PBF-LB/M process is non-linear and contradicts the idea that a ring/spot laser profile is beneficial for all laser processing technologies. This highlights the need for further research into the non-linear effect of varying intensity distributions on laser processing before the benefits of dynamic beam shaping can be truly realised.

New multi-function building plate for improving metal laser powder bed fusion by enhancing the alignment accuracy of in-process monitoring data, computed tomography measurements, and building volume geometry

AbstractLaser-based powder bed fusion of metals (PBF-LB/M) is an additive manufacturing process enabling the fabrication of parts with highly complex and customizable geometries, enhanced strength-to-weight properties, and minimized material waste. Despite its unique capabilities, PBF-LB/M needs research and innovation efforts to enhance process dynamics and product quality, as well as to broaden its adoption in high-value industrial sectors, such as aerospace and biomedical. In this context, in-process monitoring solutions and post-process part quality evaluations are fundamental to improving the process towards sustainable, first-time-right, and zero-defect production. This paper describes a novel building plate concept for metal laser powder fusion, whose characteristics were specifically designed to enable and improve the performances of in-process monitoring and high-resolution X-ray computed tomography (CT) measurements. In particular, the plate features markers for perspective correction in off-axis optical monitoring and dismountable inserts with machined geometrical elements to be used for the precise alignment between high-resolution CT reconstructions, in-process gathered data, and building volume geometry. The plate capabilities were demonstrated through examples related to in-process monitoring and post-process X-ray CT measurements.

MeltpoolGAN: Melt pool prediction from path-level thermal history

In metal laser powder bed fusion, a laser beam rapidly scans through a thin layer of powder. The laser heats up and liquefies the powder forming a melt pool. The melt pool characteristics affect the material property and physical performance of the part. Physical simulations of melt pool dynamics are computationally expensive and are often limited to a short laser scan. Alternatively, Finite Element (FE) simulations for part-scale thermal history are less computationally intensive but do not capture the detailed melt pool temperature profile and geometry in general. Accurate modeling of the high spatial and temporal thermal gradients inside and near the melt pool is essential to many applications of the thermal history including design and optimization of the laser scan path, material microstructure characterization, and deformation prediction.In this work, we developed MeltpoolGAN, the first conditional Generative Adversarial Network (cGAN) to predict the melt pool image based on the simulated thermal history along the laser scan path. The integration of generative deep learning and thermal history simulation achieves melt pool-level accuracy while significantly reducing the physical and computational complexity. The data pair of thermal history and melt pool images for neural network training and validation are obtained through Contact-Aware Path Level (CAPL) thermal simulation and a co-axial melt pool monitoring system developed by NIST, respectively. The predicted melt pool morphology is validated against experimentally acquired melt pool images through geometric characteristics, including the length and width, of the melt pool.

Dispersoid coarsening and slag formation during melt-based additive manufacturing of MA754

We have assessed the structural evolution and dispersoid coarsening behaviors of the oxide dispersion-strengthened superalloy MA754 during two different melt-based additive manufacturing techniques – metal laser powder bed fusion (PBF-LB/M) and directed energy deposition (DED). The mechanically alloyed MA754 powder posed challenges for both processes due to its irregular flaky morphology and large particle size. Successful consolidation with PBF-LB/M required increasing the layer height, decreasing the scanning speed, and increasing the laser power relative to typical Ni superalloy printing parameters. The resulting materials contained residual porosity and large Y-Al-oxide slag inclusions which formed in situ. The more prolonged thermal excursion during DED resulted in even larger, mm-scale slag inclusions, which spanned several build layers. In both PBF-LB/M and DED, these inclusions grew at the expense of nanoscale dispersoids, depleting the material of this strengthening phase. These observations motivate alternative approaches for preparing dispersion-strengthened powder feedstocks besides mechanical alloying and highlight the deleterious effects of Al microalloying on dispersoid stability and structure.

Creep of IN738LC manufactured with laser powder bed fusion: effect of build orientation and twinning

ABSTRACT The microstructural anisotropy caused by the highly oriented solidification of the metal Laser Powder Bed Fusion (PBF-LB/M) process affects mechanical short- and long-term properties. Component build orientation influences grain morphology and orientation, and thus, mechanical properties. While the creep behaviour of samples manufactured parallel and perpendicular to the build direction are studied intensively, the 45° build orientation remains uncharacterised. In this study, IN738LC creep samples are manufactured via PBF-LB/M in three build orientations (0°, 45° and 90°). While the results of 90° and 0° are as expected, where 90° achieves the longest time to rupture and largest rupture strain, the 45° specimen shows the least fracture time. Differences in microstructure and twinning behaviour are identified as one of the root causes for this unexpected behaviour. This study discusses the correlation between microstructure, twinning and build orientation and their effect on creep behaviour, with special focus on the 45° build orientation.

Micro-Twinning in IN738LC Manufactured with Laser Powder Bed Fusion.

Components manufactured with Metal Laser Powder Bed Fusion (PBF-LB/M) are built in a layerwise fashion. The PBF-LB/M build orientation affects grain morphology and orientation. Depending on the build orientation, microstructures from equiaxed to textured grains can develop. In the case of a textured microstructure, a clear anisotropy of the mechanical properties affecting short- and long-term mechanical properties can be observed, which must be considered in the component design. Within the scope of this study, the IN738LC tensile and creep properties of PBF-LB/M samples manufactured in 0° (perpendicular to build direction), 45° and 90° (parallel to build direction) build orientations were investigated. While the hot tensile results (at 850 °C) are as expected, where the tensile properties of the 45° build orientation lay between those of 0° and 90°, the creep results (performed at 850 °C and 200 MPa) of the 45° build orientation show the least time to rupture. This study discusses the microstructural reasoning behind the peculiar creep behavior of 45° oriented IN738LC samples and correlates the results to heat-treated microstructures and the solidification conditions of the PBF-LB/M process itself.

Numerical investigation of residual stresses in thin-walled additively manufactured structures from selective laser melting

Selective laser melting (SLM), a metal laser powder bed fusion additive manufacturing method, involves several cycles of very high temperature gradient heating and cooling during the solidification of each layer, which can cause the accumulation of detrimental residual stresses in the 3D printed structure. This work uses a thermo-mechanical computational modeling approach to investigate the formation of residual stresses in thin-walled structures and also investigates the effects of varying taper on the evolution of residual stress profiles of the build. Three material grades; namely, Titanium alloy (Ti64), Stainless steel (SS316L) and Inconel (IN718) have been used for this study. The results show that varying taper thickness up to a certain value has a considerable effect on residual stress evolutions in thin-wall structures, however, beyond a certain value of the taper level, the residual stresses are observed to converge. Also, it is observed that the tensile stresses at the edges of the wall are almost equal or exceed the yield stress of the materials. Among the three material grades considered, the magnitude of residual stress was higher in Ti64 and the stresses are dominant in the build direction. The simulation framework is also applied to analyze the effect of residual stresses on the mechanical properties of complex thin-wall structures such as TPMS (Triply Periodic Minimum Surfaces) lattice structure, using Schwarz Primitive (SP) as a case study. It is observed that the residual stresses lower the effective elastic properties of the lattice structures by 6% ∼ 10% for the three material grades but has no effect on the effective plastic behavior of the material.

On the Use of Metal Sinter Powder in Laser Powder Bed Fusion Processing (PBF-LB/M).

Metal Laser Powder Bed Fusion (PBF-LB/M Powder Bed Fusion, Laser-Based/Metal) offers decisive advantages over conventional manufacturing processes. Complex geometries can be produced that cannot, or only to a limited extent, be manufactured with conventional manufacturing processes. One of the main disadvantages of the process are high investment and operating costs. In order to make the PBF-LB/M process accessible to new research areas, the costs need to be reduced. Therefore, this work investigates whether laser beam sources and motion systems in currently established PBF-LB/M systems can be replaced by more cost-effective components. To reduce the operating costs for PBF-LB/M, the studies are carried out based on previous work with water-atomized, process-foreign sinter powder instead of gas-atomized, spherical PBF-LB/M powders. A cost-efficient, low-alloyed powder is selected (Höganäs HP1) and processed on two different PBF-LB/M machines with a restricted process window using process parameter values that current low-cost machines can achieve. The results show that a multimode fiber laser leads to a more stable process and wider melt pools compared to a single mode fiber laser. In addition, a lower sensitivity of the process with respect to modified process parameters is observed for the multimode laser, resulting in a wider range of stable process windows. A Cartesian motion system (gantry) is suitable for use in PBF-LB/M despite lower scan speeds compared to galvanometer scanners. Beam guidance in the XY-plane offers new possibilities for machine and process design that are not possible with usual scanner systems.

Influence of build orientation on the creep behavior of IN738LC manufactured with laser powder bed fusion

While metal Laser Powder Bed Fusion (PBF-LB/M) offers many advantages, such as increased design freedom, it is yet to be accepted as a reliable manufacturing route. Due to the highly oriented solidification of the PBF-LB/M process, the microstructural anisotropy significantly affects mechanical short- and long-term properties. Component build orientation directly influences grain morphology and orientation and thus mechanical properties.In this study, IN738LC creep samples are manufactured in three build orientations (0°, 45° and 90°) using PBF-LB/M. Creep tests are carried out at 750 °C and 850 °C with applied stresses up to 350 MPa. While the results of 90° and 0° agree with the creep results of other Ni-superalloys manufactured with PBF-LB/M, where the 90° specimen achieves the longest time to rupture and largest creep strain, the 45° specimen shows differing creep results compared to other Ni-superalloys with the least time to fracture. This study discusses the correlation between microstructure and build direction and their effect on creep behavior, especially on the 45° specimen.

Production of the cylinder head and crankcase of a small internal combustion engine using metal laser powder bed fusion

This effort investigates the use of metal additive manufacturing, specifically laser powder bed fusion (LPBF) for the automotive and defense industries by demonstrating its feasibility to produce working internal combustion (IC) engine components. Through reverse engineering, model modifications, parameter selection, build layout optimization, and support structure design, the production of a titanium crankcase and aluminum cylinder head for a small IC engine was made possible. Computed tomography (CT) scans were subsequently used to quantify whether defects such as cracks, geometric deviations, and porosity were present or critical. Once viability of the parts was established, machining and other post-possessing were completed to create functional parts. Final X-ray CT and micro-CT results showed all critical features fell within ±0.127 mm of the original equipment manufacturer (OEM) parts. This allowed reassembly of the engine without any issues hindering later successful operation. Furthermore, the LPBF parts had significantly reduced porosity percentages, potentially making them more robust than their cast counterparts.

On the use of X-ray computed tomography for the improvement of metal laser powder bed fusion process monitoring

Laser-powder bed fusion (LPBF) is increasingly used as a successful metal additive manufacturing technology in different industrial sectors, such as biomedical and aerospace, especially for the production of parts with high geometrical complexity. However, LPBF is still affected by repeatability issues and the presence of several defects within the fabricated components. This aspect is therefore a hindrance in the spreading of this prospective technology, which in several cases is still not able to meet the stringent quality requirements imposed by such industries. In order to overcome these issues, X-ray computed tomography (CT) acquires a fundamental role in the understanding of critical aspects and for process development and optimization. Also considering the growing interest regarding the development of LPBF process monitoring systems, which seek to identify and possibly correct defects during fabrication, CT is very much needed for the generation of reference data concerning actual geometry and internal defects. Nevertheless, this implies the need for an accurate comparison between datasets obtained by in-process acquisitions and post-process measurements, with the aim of successfully correlating process events to actual defects. However, to enhance the comparison accuracy, deformations occurring during and after manufacturing need to be considered when performing in- and post-process data registration, given that this aspect is greatly affecting the outcome of correlations. This work studies a sample geometry that is specifically developed for enhancing data registration accuracy, along with the related alignment procedure. The methodology has also the advantage to be applicable to any kind of in-process monitoring data, despite this paper uses optical imaging for the acquisition of long-exposure digital images, which proved to be suited for detecting spatter particles. Post-process datasets were obtained through metrological X-ray computed tomography, which provides detailed information regarding internal defects.

Multi-Response Optimization of Ti6Al4V Support Structures for Laser Powder Bed Fusion Systems

Laser Powder Bed Fusion (LPBF) is one of the most commonly used and rapidly developing metal Additive Manufacturing (AM) technologies for producing optimized geometries, complex features, and lightweight components, in contrast to traditional manufacturing, which limits those characteristics. However, this technology faces difficulties with regard to the construction of overhang structures and warping deformation caused by thermal stresses. Producing overhangs without support structures results in collapsed parts, while adding unnecessary supports increases the material required and post-processing. The purpose of this study was to evaluate the various support and process parameters for metal LPBF, and propose optimized support structures to minimize Support Volume, Support Removal Effort, and Warping Deformation. The optimization approach was based on the Design of Experiments (DOE) methodology and multi-response optimization, by 3D printing and studying overhang geometries from 0° to 45°. For this purpose, EOS Titanium Ti64 Grade 5 powder was used, a Ti6Al4V alloy commonly employed in LPBF. For 0° overhangs, the optimum solution was characterized by an average Tooth Height, large Tooth Top Length, low X, Y Hatching, and high Laser Speed, while for 22.5° and 45° overhangs, it was characterized by large Tooth Height, low Tooth Top Length, high X, Y Hatching, and high Laser Speed.

Fatigue prediction and life assessment method for metal laser powder bed fusion parts

In this paper, an industry-accepted fatigue model based on generalized stress-life (S–N) curves is adapted for metal parts fabricated by laser powder bed fusion (LPBF). Initial defects inherent to the fabrication process, such as part porosity, are related to fatigue life performance. Hereto, additively manufactured test specimens are fatigue tested and used to formulate a function to predict fatigue life based on the size of initial defects. The predictions correlate well with experimental results and provide a quality measure to expel outliers. The method can be used to predict the life expectancy of LPBF parts based on a priori detected defect sizes.

MONITORING FOR CRACKS IN METAL L-PBF USING GAS-BORNE ACOUSTIC EMISSION

Delaminations and cracks are detrimental phenomena that hinder the quality of the final product in metal additive manufacturing. The effective use of other online monitoring systems that can detect these deformations and delaminations during the manufacturing process is currently being developed and implemented in practice. In this paper, gas-borne acoustic emission is used to show that cracks/delaminations that occur during the metal laser powder bed fusion build process can be detected and distinguished from other machine noise. The peaks in the amplitude of the signal emitted in the time domain could be used to indicate the occurrence of cracks during the build process. The frequency characteristics of the signal could also clearly indicate the occurrence of the macro cracks and differentiate between the signals from the cracks and the machine noise.

Impacts of microsecond control in laser powder bed fusion processing

Lasers used in standard metal Laser Powder Bed Fusion (LPBF) machines are focused at the build plane with typical beam diameters less than 100 µm. This results in millions of individual laser beam scanning vectors when fabricating complex metal parts, and in most build scenarios, the laser turns on and off at the beginning and end of each vector, respectively. The standard configuration for LPBF machines includes a laser beam steering system with two mirrors attached to galvanometers, called the scanner. Most commercial lasers have response times for beam power control below 10 µs yet acceleration/deceleration times of commercial scanners are an order of magnitude slower (due to the dynamics of the mechanical system). A common strategy for allowing the scanner to “catch up” with the commanded location and speed is to employ “skywriting” with additional built-in time delays to allow for the scanner to maintain constant velocity while the laser is on. These delays along with skywriting are intended to increase resolution and reduce defects, although the actions and times are typically not accessible by the user. In fact, the millions of laser on/off events result in additional sources for defect generation to include lack of fusion voids, keyhole voids, surface roughness, and spatter. Ultimately, this results in differences in part performance within builds (build location) and between LPBF platforms. Recent work has identified methods to eliminate some forms of laser on/off defects by controlling the laser power ramp rate. To the authors knowledge, laser power ramping is not currently implemented on any commercial LPBF machine, and the use of laser power ramping has yet to be evaluated on realistic, complex parts. As a result, the current work implemented laser power ramping on a commercial LPBF machine using a complicated geometry with 1,309,338 laser on/off events (vectors) to analyze the holistic impact of fabricating real parts on defects, mechanical properties, and spatter. Ramping the laser power over 300µs eliminated the formation of back spatter, and a demonstration build of a complex qualification test artifact using IN718 reduced total spatter by nearly 5%. However, this laser power ramp change over 300µs (i.e., linearly varying laser power from 0 W to the desired power set point over 300µs) increased lack of fusion defects near part edges that reduced the tensile ductility from 17% to 12% without affecting tensile strength. The research highlighted the financial challenges imposed when scrutinizing microsecond level interactions, and as a result, a low-cost method to identify minimum ramp rates to prevent back spatter using a smart phone and an optical microscope was demonstrated. Microsecond control over the laser must be accompanied by microsecond control of the scanner and the impacts must be quantified holistically over a variety of response variables to broadly apply the developments to industry applications.1

Quality Quantification and Control via Novel Self-Growing Process-Quality Model of Parts Fabricated by LPBF Process.

Laser Powder Bed Fusion (LPBF) presents a more extensive allowable design complexity and manufacturability compared with the traditional manufacturing processes by depositing materials in a layer-wised manner. However, the process variability in the LPBF process induces quality uncertainty and inconsistency. Specifically, the mechanical properties, e.g., tensile strength, are hard to be predicted and controlled in the LPBF process. Much research has recently been reported exploring the qualitative influence of single/two process parameters on tensile strength. In fact, mechanical properties are comprehensively affected by multiple correlated process parameters with unclear and complex interactions. Thus, the study on the quantitative process-quality model of the metal LPBF process is urgently needed to provide an enough-strength component via the metal LPBF process. Recent progress in artificial intelligence (AI) and machine learning (ML) provides new insight into quality prediction in terms of computational accuracy and speed. However, the predictive model quality through the traditional AL/ML is heavily determined by the training data size, and the experimental analysis can be expansive on LPBF. This paper explores the comprehensive effect of the tensile strength of 316L stainless-steel parts on LPBF and proposes a valid quantitative predictive model through a novel self-growing machine-learning framework. The self-growing framework can autonomously expand and classify the growing dataset to provide a high-accuracy prediction with fewer input data. To verify this predictive model of tensile strength, specimens manufactured by the LPBF process with different group process parameters (laser power, scanning speed, and hatch spacing) are collected. The experimental results validate the predicted tensile strengths within a less than 3% deviation.

Characterizing Nanoparticle Release Patterns of Laser Powder Bed Fusion in Metal Additive Manufacturing: First Step Towards Mitigation Measures.

Laser Powder Bed Fusion (L-PBF) is a well-known Additive Manufacturing (AM) technology with a wide range of industrial applications. Potential occupational exposures to metal nanoparticles (NP) as by-products could occur in these processes, and no cogent occupational exposure limits are available. To contribute to this assessment, a monitoring campaign to measure the NP release pattern in two metal L-PBF facilities was carried out in two academic laboratories adopting L-PBF technology for research purposes. The monitored processes deal with two devices and three feedstock types, namely stainless steel (AISI 316L), aluminium-silicon alloy (A357) and pure copper, which are associated with different levels of industrial maturity. Prolonged environmental and personal real-time monitoring of NP concentration and size were performed, temperature and relative humidity were also measured during environmental monitoring. The measurements reveal a controlled NP release of the monitored processes, resulting in an average reduced exposure of the operators during the whole working shift, in compliance with proposed limit values (20 000 n cm-3 for density >6000 kg m-3 or 40 000 n cm-3 for density <6000 kg m-3). Nonetheless, the monitoring results show release events with an increase in NP concentration and a decrease in NP size corresponding with several actions usually performed during warm-up and cleaning, leading to exposures over 40-50 000 n cm-3 during a considerable time interval, especially during the manufacturing of pure copper powder. The results show that the actions of the operators, boundary conditions (relative humidity) and set-up of the L-PBF device have an impact on the amount of NP released and their size. Several release events (significant increase in NP concentration and decrease in NP size) are identified and associated with specific job tasks of the workers as well as building conditions. These results contribute to the definition of NP release benchmarks in AM processes and provide information to improve the operational conditions of L-PBF processes as well as safety guidelines for operators.

Unit-Based Design of Cross-Flow Heat Exchangers for LPBF Additive Manufacturing

Abstract The structural design and additive manufacturing (AM) of cross-flow heat exchangers (HXs) are studied. A unit-based design framework is proposed to optimize the channel configuration in order to improve the heat exchange performance (HXP) and meanwhile control the pressure drop (PD) between the fluid inlet and outlet. A gradient-based optimization methodology is employed to drive the design process. Both shape and topology changes are observed during the channel configuration evolution. Moreover, AM printability evaluation is considered and some re-design work is proposed to improve the printability of the designs with respect to the metal laser powder bed fusion (LPBF) process. For an optimized structure from the unit-based design, corner rounding operation is adopted first, specifically to avoid sharp features. Then the building process of the entire HX containing top, bottom caps, side walls, and the optimized thin-walled channels is simulated, and residual deformation is predicted through sequential layer-by-layer analysis. Based on the residual deformation profile, geometrical compensation is implemented to reduce geometrical inaccuracy of the printed HX. In addition, build orientation selection is also studied to avoid overhang issues in some specific unit-based design results. Finally, a mature design scheme for the cross-flow HX can be achieved as the solution that leads to largely improved HXP (e.g., nearly 200% increase), well controlled PD, and enhanced printability with respect to the LPBF AM process.