Thermophysical Phenomena in Metal Additive Manufacturing by Selective Laser Melting: Fundamentals, Modeling, Simulation and Experimentation

Among the many additive manufacturing (AM) processes for metallic materials, selective laser melting (SLM) is arguably the most versatile in terms of its potential to realize complex geometries along with tailored microstructure. However, the complexity of the SLM process, and the need for predictive relation of powder and process parameters to the part properties, demands further development of computational and experimental methods. This review addresses the fundamental physical phenomena of SLM, with a special emphasis on the associated thermal behavior. Simulation and experimental methods are discussed according to three primary categories. First, macroscopic approaches aim to answer questions at the component level and consider for example the determination of residual stresses or dimensional distortion effects prevalent in SLM. Second, mesoscopic approaches focus on the detection of defects such as excessive surface roughness, residual porosity or inclusions that occur at the mesoscopic length scale of individual powder particles. Third, microscopic approaches investigate the metallurgical microstructure evolution resulting from the high temperature gradients and extreme heating and cooling rates induced by the SLM process. Consideration of physical phenomena on all of these three length scales is mandatory to establish the understanding needed to realize high part quality in many applications, and to fully exploit the potential of SLM and related metal AM processes

On-sky wide field adaptive optics correction using multiple laser guide stars at the MMT

We describe results from the first astronomical adaptive optics system to use multiple laser guide stars, located at the 6.5-m MMT telescope in Arizona. Its initial operational mode, ground-layer adaptive optics (GLAO), provides uniform stellar wavefront correction within the 2 arc minute diameter laser beacon constellation, reducing the stellar image widths by as much as 53%, from 0.70 to 0.33 arc seconds at lambda = 2.14 microns. GLAO is achieved by applying a correction to the telescope's adaptive secondary mirror that is an average of wavefront measurements from five laser beacons supplemented with image motion from a faint stellar source. Optimization of the adaptive optics system in subsequent commissioning runs will further improve correction performance where it is predicted to deliver 0.1 to 0.2 arc second resolution in the near-infrared during a majority of seeing conditions.Comment: 13 pages, 1 table, 7 figures. Accepted for publication in Astrophysical Journal. Expected March 200

Inducing Transport in a Dissipation-Free Lattice with Super Bloch Oscillations

Particles in a perfect lattice potential perform Bloch oscillations when subject to a constant force, leading to localization and preventing conductivity. For a weakly-interacting Bose-Einstein condensate (BEC) of Cs atoms, we observe giant center-of-mass oscillations in position space with a displacement across hundreds of lattice sites when we add a periodic modulation to the force near the Bloch frequency. We study the dependence of these "super" Bloch oscillations on lattice depth, modulation amplitude, and modulation frequency and show that they provide a means to induce linear transport in a dissipation-free lattice. Surprisingly, we find that, for an interacting quantum system, super Bloch oscillations strongly suppress the appearance of dynamical instabilities and, for our parameters, increase the phase-coherence time by more than a factor of hundred.Comment: 4 pages, 5 figure

Confinement-Induced Resonances in Low-Dimensional Quantum Systems

We report on the observation of confinement-induced resonances in strongly interacting quantum-gas systems with tunable interactions for one- and two-dimensional geometry. Atom-atom scattering is substantially modified when the s-wave scattering length approaches the length scale associated with the tight transversal confinement, leading to characteristic loss and heating signatures. Upon introducing an anisotropy for the transversal confinement we observe a splitting of the confinement-induced resonance. With increasing anisotropy additional resonances appear. In the limit of a two-dimensional system we find that one resonance persists.Comment: 4 pages, 4 figure

Ground-layer wavefront reconstruction from multiple natural guide stars

Observational tests of ground layer wavefront recovery have been made in open loop using a constellation of four natural guide stars at the 1.55 m Kuiper telescope in Arizona. Such tests explore the effectiveness of wide-field seeing improvement by correction of low-lying atmospheric turbulence with ground-layer adaptive optics (GLAO). The wavefronts from the four stars were measured simultaneously on a Shack-Hartmann wavefront sensor (WFS). The WFS placed a 5 x 5 array of square subapertures across the pupil of the telescope, allowing for wavefront reconstruction up to the fifth radial Zernike order. We find that the wavefront aberration in each star can be roughly halved by subtracting the average of the wavefronts from the other three stars. Wavefront correction on this basis leads to a reduction in width of the seeing-limited stellar image by up to a factor of 3, with image sharpening effective from the visible to near infrared wavelengths over a field of at least 2 arc minutes. We conclude that GLAO correction will be a valuable tool that can increase resolution and spectrographic throughput across a broad range of seeing-limited observations.Comment: 25 pages, 8 figures, to be published in Astrophys.

A novel smoothed particle hydrodynamics formulation for thermo-capillary phase change problems with focus on metal additive manufacturing melt pool modeling

Laser-based metal processing including welding and three dimensional printing, involves localized melting of solid or granular raw material, surface tension-driven melt flow and significant evaporation of melt due to the applied very high energy densities. The present work proposes a weakly compressible smoothed particle hydrodynamics formulation for thermo-capillary phase change problems involving solid, liquid and gaseous phases with special focus on selective laser melting, an emerging metal additive manufacturing technique. Evaporation-induced recoil pressure, temperature-dependent surface tension and wetting forces are considered as mechanical interface fluxes, while a Gaussian laser beam heat source and evaporation-induced heat losses are considered as thermal interface fluxes. A novel interface stabilization scheme is proposed, which is shown to allow for a stable and smooth liquid-gas interface by effectively damping spurious interface flows as typically occurring in continuum surface force approaches. Moreover, discretization strategies for the tangential projection of the temperature gradient, as required for the discrete Marangoni forces, are critically reviewed. The proposed formulation is deemed especially suitable for modeling of the melt pool dynamics in metal additive manufacturing because the full range of relevant interface forces is considered and the explicit resolution of the atmospheric gas phase enables a consistent description of pore formation by gas inclusion. The accuracy and robustness of the individual model and method building blocks is verified by means of several selected examples in the context of the selective laser melting process

Novel Simulation-Inspired Roller Spreading Strategies for Fine and Highly Cohesive Metal Powders

When fine powders are to be used in powder bed metal additive manufacturing (AM), a roller is typically utilized for spreading. However, the cohesive nature of fine metal powder still presents challenges, resulting in low density and/or inconsistent layers under sub-standard spreading conditions. Here, through computational parameter studies with an integrated discrete element-finite element (DEM-FEM) framework, we explore roller-based strategies that are predicted to achieve highly cohesive powder layers. The exemplary feedstock is a Ti-6Al-4V 0-20 um powder, that is emulated using a self-similarity approach based on experimental calibration. The computational studies explore novel roller kinematics including counter-rotation as well as angular and transverse oscillation applied to standard rigid rollers as well as coated rollers with compliant or non-adhesive surfaces. The results indicate that most of these approaches allow to successfully spread highly cohesive powders with high packing fraction (between 50%-60% in a single layer) and layer uniformity provided that the angular/oscillatory, relative to the transverse velocity, as well as the surface friction of the roller are sufficiently high. Critically, these spreading approaches are shown to be very robust with respect to varying substrate conditions (simulated by means of a decrease in surface energy), which are likely to occur in LBPF or BJ, where substrate characteristics are the result of a complex multi-physics (i.e., powder melting or binder infiltration) process. In particular, the combination of the identified roller kinematics with compliant surface coatings, which are known to reduce the risk of tool damage and particle streaking in the layers, is recommended for future experimental investigation