In situ melt pool measurements for laser powder bed fusion using multi sensing and correlation analysis

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dc.contributor.authorWang, Rongxuanen
dc.contributor.authorGarcia, Daviden
dc.contributor.authorKamath, Rakesh R.en
dc.contributor.authorDou, Chaoranen
dc.contributor.authorMa, Xiaohanen
dc.contributor.authorShen, Boen
dc.contributor.authorChoo, Hahnen
dc.contributor.authorFezzaa, Kamelen
dc.contributor.authorYu, Hang Z.en
dc.contributor.authorKong, Zhenyu (James)en
dc.date.accessioned2022-10-18T13:13:12Zen
dc.date.available2022-10-18T13:13:12Zen
dc.date.issued2022-08-12en
dc.description.abstractLaser powder bed fusion is a promising technology for local deposition and microstructure control, but it suffers from defects such as delamination and porosity due to the lack of understanding of melt pool dynamics. To study the fundamental behavior of the melt pool, both geometric and thermal sensing with high spatial and temporal resolutions are necessary. This work applies and integrates three advanced sensing technologies: synchrotron X-ray imaging, high-speed IR camera, and high-spatial-resolution IR camera to characterize the evolution of the melt pool shape, keyhole, vapor plume, and thermal evolution in Ti-6Al-4V and 410 stainless steel spot melt cases. Aside from presenting the sensing capability, this paper develops an effective algorithm for high-speed X-ray imaging data to identify melt pool geometries accurately. Preprocessing methods are also implemented for the IR data to estimate the emissivity value and extrapolate the saturated pixels. Quantifications on boundary velocities, melt pool dimensions, thermal gradients, and cooling rates are performed, enabling future comprehensive melt pool dynamics and microstructure analysis. The study discovers a strong correlation between the thermal and X-ray data, demonstrating the feasibility of using relatively cheap IR cameras to predict features that currently can only be captured using costly synchrotron X-ray imaging. Such correlation can be used for future thermal-based melt pool control and model validation.en
dc.description.notesResearch reported in this publication was supported by the Office of Naval Research under Award Number N00014-18-1-2794<BOLD>.</BOLD> We would like to thank Alex Deriy from APS for assisting with the beamline experiments; Thomas Feldhausen from Oak Ridge National Lab for preparing the SS-410 samples; Scott Lancaster and Randall Waldron from Virginia Tech for assisting with the high-spatial IR fixture fabrication.en
dc.description.sponsorshipOffice of Naval Research [N00014-18-1-2794]en
dc.description.versionPublished versionen
dc.format.mimetypeapplication/pdfen
dc.identifier.doihttps://doi.org/10.1038/s41598-022-18096-wen
dc.identifier.issn2045-2322en
dc.identifier.issue1en
dc.identifier.other13716en
dc.identifier.pmid35962031en
dc.identifier.urihttp://hdl.handle.net/10919/112189en
dc.identifier.volume12en
dc.language.isoenen
dc.publisherNature Portfolioen
dc.rightsCreative Commons Attribution 4.0 Internationalen
dc.rights.urihttp://creativecommons.org/licenses/by/4.0/en
dc.subjectfinite-element simulationen
dc.subjectphase-transformationen
dc.subjectheat-transferen
dc.subjectmicrostructureen
dc.subjectdynamicsen
dc.subjecttemperatureen
dc.subjectti-6al-4ven
dc.subjectpenetrationen
dc.subjectmorphologyen
dc.subjectstressen
dc.titleIn situ melt pool measurements for laser powder bed fusion using multi sensing and correlation analysisen
dc.title.serialScientific Reportsen
dc.typeArticle - Refereeden
dc.type.dcmitypeTexten

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