Thermoelectric magnetohydrodynamic control of melt pool flow during laser directed energy deposition additive manufacturing

Xianqiang Fan; Tristan G. Fleming; David T. Rees; Yuze Huang; Sebastian Marussi; Chu Lun Alex Leung; Robert C. Atwood; Andrew Kao; Peter D. Lee

doi:10.1016/j.addma.2023.103587

Thermoelectric magnetohydrodynamic control of melt pool flow during laser directed energy deposition additive manufacturing

Xianqiang Fan, Tristan G. Fleming, David T. Rees, Yuze Huang, Sebastian Marussi, Chu Lun Alex Leung, Robert C. Atwood, Andrew Kao, Peter D. Lee

Centre for Manufacturing and Materials

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

30 Citations (Scopus)

123 Downloads (Pure)

Abstract

Melt flow is critical to build quality during additive manufacturing (AM). When an external magnetic field is applied, it causes forces that alter the flow through the thermoelectric magnetohydrodynamic (TEMHD) effect, potentially altering the final microstructure. However, the extent of TEMHD forces and their underlying mechanisms, remain unclear. We trace the flow of tungsten particles using in situ high-speed synchrotron X-ray radiography and ex situ tomography to reveal the structure of TEMHD-induced flow during directed energy deposition AM (DED-AM). When no magnetic field is imposed, Marangoni convection dominates the flow, leading to a relatively even particle distribution. With a magnetic field parallel to the scan direction, TEMHD flow is induced, circulating in the cross-sectional plane, causing particle segregation to the bottom and side of the pool. Further, a downward magnetic field causes horizontal circulation, segregating particles to the other side. Our results demonstrate that TEMHD can disrupt melt pool flow during DED-AM.

Original language	English
Article number	103587
Number of pages	11
Journal	Additive Manufacturing
Volume	71
Early online date	3 May 2023
DOIs	https://doi.org/10.1016/j.addma.2023.103587
Publication status	Published - 5 Jun 2023

Bibliographical note

This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).

Funder

This research was supported under MAPP: UK-EPSRC Future Manufacturing Hub in Manufacture using Advanced Powder Processes (EP/P006566/1) and a Royal Academy of Engineering Chair in Emerging Technologies (CiET1819/10). The authors acknowledge UK-EPSRC support (grants EP/W031167/1, EP/W032147/1, EP/W037483/1, EP/W006774/1, EP/W003333/1, EP/V061798/1). XF acknowledges the China Scholarship Council. DTR acknowledges a Rolls-Royce plc. and EPSRC-iCASE.

Keywords

Additive manufacturing
Melt flow control
Thermoelectric magnetohydrodynamic
Magnetic fields
Tungsten tracer

ASJC Scopus subject areas

Biomedical Engineering
General Materials Science
Engineering (miscellaneous)
Industrial and Manufacturing Engineering

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10.1016/j.addma.2023.103587Licence: CC BY

PublishedFinal published version, 8.61 MBLicence: CC BY

Cite this

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title = "Thermoelectric magnetohydrodynamic control of melt pool flow during laser directed energy deposition additive manufacturing",

abstract = "Melt flow is critical to build quality during additive manufacturing (AM). When an external magnetic field is applied, it causes forces that alter the flow through the thermoelectric magnetohydrodynamic (TEMHD) effect, potentially altering the final microstructure. However, the extent of TEMHD forces and their underlying mechanisms, remain unclear. We trace the flow of tungsten particles using in situ high-speed synchrotron X-ray radiography and ex situ tomography to reveal the structure of TEMHD-induced flow during directed energy deposition AM (DED-AM). When no magnetic field is imposed, Marangoni convection dominates the flow, leading to a relatively even particle distribution. With a magnetic field parallel to the scan direction, TEMHD flow is induced, circulating in the cross-sectional plane, causing particle segregation to the bottom and side of the pool. Further, a downward magnetic field causes horizontal circulation, segregating particles to the other side. Our results demonstrate that TEMHD can disrupt melt pool flow during DED-AM.",

keywords = "Additive manufacturing, Melt flow control, Thermoelectric magnetohydrodynamic, Magnetic fields, Tungsten tracer",

author = "Xianqiang Fan and Fleming, {Tristan G.} and Rees, {David T.} and Yuze Huang and Sebastian Marussi and Leung, {Chu Lun Alex} and Atwood, {Robert C.} and Andrew Kao and Lee, {Peter D.}",

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AU - Fan, Xianqiang

AU - Fleming, Tristan G.

AU - Rees, David T.

AU - Huang, Yuze

AU - Marussi, Sebastian

AU - Leung, Chu Lun Alex

AU - Atwood, Robert C.

AU - Kao, Andrew

AU - Lee, Peter D.

N1 - This is an open access article under the CC BY license (http://creativecommons.org/licenses/by/4.0/).

PY - 2023/6/5

Y1 - 2023/6/5

N2 - Melt flow is critical to build quality during additive manufacturing (AM). When an external magnetic field is applied, it causes forces that alter the flow through the thermoelectric magnetohydrodynamic (TEMHD) effect, potentially altering the final microstructure. However, the extent of TEMHD forces and their underlying mechanisms, remain unclear. We trace the flow of tungsten particles using in situ high-speed synchrotron X-ray radiography and ex situ tomography to reveal the structure of TEMHD-induced flow during directed energy deposition AM (DED-AM). When no magnetic field is imposed, Marangoni convection dominates the flow, leading to a relatively even particle distribution. With a magnetic field parallel to the scan direction, TEMHD flow is induced, circulating in the cross-sectional plane, causing particle segregation to the bottom and side of the pool. Further, a downward magnetic field causes horizontal circulation, segregating particles to the other side. Our results demonstrate that TEMHD can disrupt melt pool flow during DED-AM.

AB - Melt flow is critical to build quality during additive manufacturing (AM). When an external magnetic field is applied, it causes forces that alter the flow through the thermoelectric magnetohydrodynamic (TEMHD) effect, potentially altering the final microstructure. However, the extent of TEMHD forces and their underlying mechanisms, remain unclear. We trace the flow of tungsten particles using in situ high-speed synchrotron X-ray radiography and ex situ tomography to reveal the structure of TEMHD-induced flow during directed energy deposition AM (DED-AM). When no magnetic field is imposed, Marangoni convection dominates the flow, leading to a relatively even particle distribution. With a magnetic field parallel to the scan direction, TEMHD flow is induced, circulating in the cross-sectional plane, causing particle segregation to the bottom and side of the pool. Further, a downward magnetic field causes horizontal circulation, segregating particles to the other side. Our results demonstrate that TEMHD can disrupt melt pool flow during DED-AM.

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KW - Magnetic fields

KW - Tungsten tracer

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Thermoelectric magnetohydrodynamic control of melt pool flow during laser directed energy deposition additive manufacturing

Abstract

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