In situ X-ray quantification of melt pool behaviour during directed energy deposition additive manufacturing of stainless steel

Yunhui Chen; Samuel J. Clark; Yuze Huang; Lorna Sinclair; Chu Lun Alex Leung; Sebastian Marussi; Thomas Connolley; Oxana V. Magdysyuk; Robert C. Atwood; Gavin J. Baxter; Martyn A. Jones; Iain Todd; Peter D. Lee

doi:10.1016/j.matlet.2020.129205

In situ X-ray quantification of melt pool behaviour during directed energy deposition additive manufacturing of stainless steel

Yunhui Chen, Samuel J. Clark, Yuze Huang, Lorna Sinclair, Chu Lun Alex Leung, Sebastian Marussi, Thomas Connolley, Oxana V. Magdysyuk, Robert C. Atwood, Gavin J. Baxter, Martyn A. Jones, Iain Todd, Peter D. Lee

Research output: Contribution to journal › Article › peer-review

33 Citations (Scopus)

Abstract

The Directed Energy Deposition Additive Manufacturing (DED-AM) of SS316L was studied using in situ and operando synchrotron X-ray imaging to quantitively understand the effect of processing parameters on the melt-pool morphology and surface quality. It was found that surface roughness of DED-AM builds can result from melt pool surface perturbations caused by changes in the melt flow and build stage motion perturbations. Process maps are developed that quantitatively correlate build quality to process parameters including powder feed rate, laser power and traverse speed. How the AM process parameters control build efficacy is clarified, and the processing conditions required to dampen surface perturbations leading to roughness were determined.

Original language	English
Article number	129205
Journal	Materials Letters
Volume	286
Early online date	13 Dec 2020
DOIs	https://doi.org/10.1016/j.matlet.2020.129205
Publication status	Published - Mar 2021
Externally published	Yes

Keywords

Directed energy deposition
In situ synchrotron X-ray imagin
Laser additive manufacturing

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10.1016/j.matlet.2020.129205

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Chen, Y., Clark, S. J., Huang, Y., Sinclair, L., Leung, C. L. A., Marussi, S., Connolley, T., Magdysyuk, O. V., Atwood, R. C., Baxter, G. J., Jones, M. A., Todd, I., & Lee, P. D. (2021). In situ X-ray quantification of melt pool behaviour during directed energy deposition additive manufacturing of stainless steel. Materials Letters, 286, Article 129205. https://doi.org/10.1016/j.matlet.2020.129205

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title = "In situ X-ray quantification of melt pool behaviour during directed energy deposition additive manufacturing of stainless steel",

abstract = "The Directed Energy Deposition Additive Manufacturing (DED-AM) of SS316L was studied using in situ and operando synchrotron X-ray imaging to quantitively understand the effect of processing parameters on the melt-pool morphology and surface quality. It was found that surface roughness of DED-AM builds can result from melt pool surface perturbations caused by changes in the melt flow and build stage motion perturbations. Process maps are developed that quantitatively correlate build quality to process parameters including powder feed rate, laser power and traverse speed. How the AM process parameters control build efficacy is clarified, and the processing conditions required to dampen surface perturbations leading to roughness were determined.",

keywords = "Directed energy deposition, In situ synchrotron X-ray imagin, Laser additive manufacturing",

author = "Yunhui Chen and Clark, {Samuel J.} and Yuze Huang and Lorna Sinclair and Leung, {Chu Lun Alex} and Sebastian Marussi and Thomas Connolley and Magdysyuk, {Oxana V.} and Atwood, {Robert C.} and Baxter, {Gavin J.} and Jones, {Martyn A.} and Iain Todd and Lee, {Peter D.}",

year = "2021",

month = mar,

doi = "10.1016/j.matlet.2020.129205",

language = "English",

volume = "286",

journal = "Materials Letters",

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TY - JOUR

T1 - In situ X-ray quantification of melt pool behaviour during directed energy deposition additive manufacturing of stainless steel

AU - Chen, Yunhui

AU - Clark, Samuel J.

AU - Huang, Yuze

AU - Sinclair, Lorna

AU - Leung, Chu Lun Alex

AU - Marussi, Sebastian

AU - Connolley, Thomas

AU - Magdysyuk, Oxana V.

AU - Atwood, Robert C.

AU - Baxter, Gavin J.

AU - Jones, Martyn A.

AU - Todd, Iain

AU - Lee, Peter D.

PY - 2021/3

Y1 - 2021/3

N2 - The Directed Energy Deposition Additive Manufacturing (DED-AM) of SS316L was studied using in situ and operando synchrotron X-ray imaging to quantitively understand the effect of processing parameters on the melt-pool morphology and surface quality. It was found that surface roughness of DED-AM builds can result from melt pool surface perturbations caused by changes in the melt flow and build stage motion perturbations. Process maps are developed that quantitatively correlate build quality to process parameters including powder feed rate, laser power and traverse speed. How the AM process parameters control build efficacy is clarified, and the processing conditions required to dampen surface perturbations leading to roughness were determined.

AB - The Directed Energy Deposition Additive Manufacturing (DED-AM) of SS316L was studied using in situ and operando synchrotron X-ray imaging to quantitively understand the effect of processing parameters on the melt-pool morphology and surface quality. It was found that surface roughness of DED-AM builds can result from melt pool surface perturbations caused by changes in the melt flow and build stage motion perturbations. Process maps are developed that quantitatively correlate build quality to process parameters including powder feed rate, laser power and traverse speed. How the AM process parameters control build efficacy is clarified, and the processing conditions required to dampen surface perturbations leading to roughness were determined.

KW - Directed energy deposition

KW - In situ synchrotron X-ray imagin

KW - Laser additive manufacturing

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U2 - 10.1016/j.matlet.2020.129205

DO - 10.1016/j.matlet.2020.129205

M3 - Article

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VL - 286

JO - Materials Letters

JF - Materials Letters

M1 - 129205

ER -

In situ X-ray quantification of melt pool behaviour during directed energy deposition additive manufacturing of stainless steel

Abstract

Keywords

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