Layer-to-Layer Melt Pool Control in Laser Power Bed Fusion

Additive manufacturing processes are flexible and efficient technologies for producing complex geometries. However, ensuring reliability and repeatability is challenging due to the complex physics and various sources of uncertainty in the process. In this work, we investigate closed-loop control of the melt pool dimensions in a laser powder bed fusion (LPBF) process. We propose a trajectory optimization-based layer-to-layer controller that adjusts the laser power input to the next layer to track a desired melt pool depth and validate our controller by placing it in closed-loop high-fidelity multi-layer smoothed particle hydrodynamics simulator of a 2D LPBF process. Detailed numerical case studies demonstrate successful regulation of the melt pool depth on brick and overhang geometries and provide first of its kind results on the effectiveness of layer-to-layer input optimization for the LPBF process as well as detailed insight into the physics of the controlled process. Computational complexity and process performance results illustrate the method's effectiveness and provide an outlook for its implementation onto real systems

High cycle fatigue and ratcheting interaction of laser powder bed fusion stainless steel 316L:Fracture behaviour and stress-based modelling

Variations in the physical and mechanical properties of parts made by laser power bed fusion (L-PBF) could be affected by the choice of processing or post-processing strategies. This work examined the influence of build orientation and post-processing treatments (annealing or hot isostatic pressing) on the fatigue and fracture behaviours of L-PBF stainless steel 316L in the high cycle fatigue region, i.e. 104 – 106 cycles. Experimental results show that both factors introduce significant changes in the plastic deformation properties, which affect fatigue strength via the mechanism of fatigue-ratcheting interaction. Cyclic plasticity is characterised by hardening, which promotes mean stress insensitivity and improved fatigue resistance. Fatigue activities, involving the initiation of crack at defects and microstructural heterogeneities, are of greater relevance to the longer life region where the global deformation mode is elastic. As the simultaneous actions of ratcheting and fatigue generate complex nonlinear interactions between the alternating stress amplitude and mean stress, the fatigue properties could not be effectively predicted using traditional stress-based models. A modification to the Goodman relation was proposed to account for the added effects of cyclic plasticity and was demonstrated to produce good agreement with experimental results for both cyclic hardening and softening materials.EDB (Economic Devt. Board, S’pore)Accepted versio

Disentangled UHMWPE@silica powders for potential use in power bed fusion based additive manufacturing

Disentangled ultrahigh molecular weight polyethylene dUHMWPE (Mw ∼ 2.106 Da) particles in a reactor blend with HDPE are catalytically prepared from ethylene, mediated by a new catalyst from N,N'-(2,6-pyridinediyl diethylidyne) bis[2,6-di-3-propenyl-benzenamine] iron dichloride and triethyl aluminum. These particles could be laser sintered, but not automatically processed in an SLS machine. The same catalyst supported on microsilica particles gives access to composite dUHMWPE@silica particle powder with particle sizes below 200 µm. Testing bars prepared by heat pressing have an Emod of 150 MPa, an elongation at break at 450 % and an ultimate strength of 39 ± 11 MPa. A SEM image indicates a silica induced crystallization into pseudo spherulites of 500 µm size. The dUHMWPE@silica composite particles have an fcc flowability value of 3.4 in a ring shear tester, and a low density of 150 kg.m−3. Additivation with nanosilica powder (1 wt%) and carbon black (0.25 wt%) allowed to process the composite in an SLS machine. The printed parts showed severe caking, but also a complete welding of the powder, albeit with voids on account of the low particle density

Effect of heat treatments on the mechanical and microstructural behavior of a hypoeutectic Al alloy obtained by laser power bed fusion

Large gains in strength and ductility are of little significance if the material’s anisotropy is high. Therefore, improving the mechanical properties and reducing the anisotropy of Al alloys obtained by additive manufacturing is a topic of growing interest. This manuscript examines the effect of distinct heat treatments on the mechanical, anisotropic, and microstructural behavior of a hypoeutectic, almost eutectic, AlSi11Cu alloy obtained by laser powder bed fusion (L-PBF). The microstructural characterization revealed an Al matrix surrounded by a Si-rich network, forming a coral-like pattern with a heterogeneous combination of columnar and equiaxed grains. The texture indicated that the columnar grains were preferentially oriented towards the building direction with strong Cube and Goss components. Different strength-ductility ratios were obtained following the annealing and solution heat treatments at different temperatures (200 °C–550 °C) with a holding time of 1 h. In terms of grain size and dislocation density, no significant changes were found in the microstructure, suggesting that grain size and dislocation strengthening mechanisms are not highly affected by the heat treatments. In addition, the Si-enriched network remained interconnected until 300 °C. At higher temperatures, this interconnection was lost, giving rise to large Si particles depleting the Si content in solid solution in the Al matrix. Digital image correlation maps revealed that deformation fields were more homogeneous when the cellular structure disappeared. The visco-plastic self-consistent model showed that when applying the load at 30° in the building direction (BD), the largest tensile strength was generated, whereas the lowest strength was obtained when the load was parallel to the BD. Heat treatments for 1 h holding time were found to be efficient in reducing the Lankford coefficients dispersion, suggesting improvements in formability and reducing the alloy’s planar anisotropy. These results revealed that annealing up to 400 °C or higher temperatures followed by water quenching leads to good strength and ductility ratios while reducing anisotropy.Peer ReviewedPostprint (published version

NASAs Plans for Development of Standards for Additive Manufactured Components

There are currently no NASA standards providing specific design and construction requirements for certification of additively manufactured parts. Several international standards organizations are developing standards for additive manufacturing; however, NASA mission schedules preclude the Agency from relying on these organizations to develop standards that are both timely and applicable. NASA and its program partners in manned spaceflight (the Commercial Crew Program, the Space Launch System and the Orion Multi-purpose Crew Vehicle) are actively developing additively manufactured parts for flight as early as 2018. To bridge this gap, NASA Marshall Space Flight Center (MSFC) has authored a center-level standard (MSFC-STD-3716)1 to establish standard practices for the Laser Powder Bed Fusion (L-PBF) process. In its draft form, the MSFC standard has been used as a basis for L-PBF process implementation for each of the manned space flight programs. The development of an Agency-level standard is proposed, which based upon the principles of MSFC-STD-3716, would have application to multiple additive manufacturing processes and be readily adaptable to all NASA programs

Laser powder bed fusion of porous graded structures: a comparison between computational and experimental analysis

Functionally graded porous structures (FGPSs) are gaining interest in the biomedical sector, specifically for orthopaedic implants. In this study, the compressive behaviour of seven different FGPSs comprised of Face Centred Cubic (FCC) and the Octet truss unit cells (OCT) were analysed. The porosity of the structures were graded in different directions (radially, longitudinally, laterally and longitudinally & radially) by varying the strut diameters or by combining the two types of unit cells. The structures were manufactured by laser power bed fusion and compression tests were performed. Radially and laterally porous graded structures were found to outperform uniform porous structures with an increase in stiffness of 13.7% and 21.1% respectively. The experimental and finite element analysis (FEA) results were in good agreement with differences in elastic modulus of 9.4% and yield strength of 15.8%. A new FEA beam model is proposed in this study to analyse this type of structures with accurate results and the consequent reduction of computational time. The accuracy of the Kelvin-Voight model and the rule of mixtures for predicting the mechanical behaviour of different FGPSs was also investigated. The results demonstrate the adequacy of the analytical models specifically for hybrid structures and for structures with smooth diameter transitions

The Influence of Processing Parameters on the Al-Mn Enriched Nano-Precipitates Formation in a Novel Al-Mn-Cr-Zr Alloy Tailored for Power Bed Fusion-Laser Beam Process

Among the recently developed compositions tailored for the power bed fusion-laser beam process (PBF-LB), the novel Al-Mn-Cr-Zr alloy stands out. This composition exploits high solid solution strengthening, achieving a high hardness value in the as-built condition. The produced samples are inherently crack-free and have a good level of densification (similar to 99.5%). The goal of this study is to investigate how this quaternary system is affected by the laser power while retaining a similar volumetric energy density. A comparison between the microstructural features and the mechanical performance was performed on a set of samples processed with power values ranging from 100 to 170 W. Microstructural features were investigated through optical microscopy, Electron Back Scattered Diffraction (EBSD) investigation and feature analysis using advanced microscopy to examine the amount, distribution, and shape of precipitates in the different process conditions. Although the quantitative feature analysis permitted analysis of more than 60 k precipitates for each power condition, all samples demonstrated a low level of precipitation (below 0.3%) with nanometric size (around 75 nm). The mechanical performances of this quaternary system as a function of the laser power value were evaluated with a microhardness test, recording very similar values for the different process conditions with a mean value of approximately 104 HV. The results suggested a very stable system over the tested range of process parameters. In addition, considering the low level of precipitation of nanometric phases enriched in Al-Mn, a supersaturated state could be established in each process condition

Thermal analysis of parts produced by L-PBF and correlation with dimensional accuracy

Laser-Power Bed Fusion (L-PBF) is continuing to grow in use among the industrial field. This process allows the manufacturing of parts with complex geometry, good dimensional accuracy, and few post-processing steps. However, deviations can still be observed on the final parts. It is known in the literature that all of these deviations can be imputed to some extent to thermal phenomena such as overheating or thermal gradient through residual stress relaxation. The objective of this study is to reach a better understanding of the influence of the thermal properties on the dimensional accuracy of parts produced by L-PBF. To do so, an infrared camera has been instrumented inside the machine, allowing the determination of the temperature of parts during the process. Thin walls with different process parameters (laser power, scanning speed…) and nominal dimensions were manufactured and measured afterwards with a coordinate measuring machine (CMM). Thermal acquisitions were performed at different moments during the fabrication and give access to the cooling rate of the observed parts. Least square fitting has been used to approximate the cooling rate function and returns characteristic times that are used to compare the different manufacturing configurations. In the end, a correlation has been established between the process parameters, the thermal parameters, and the dimensional accuracy of the parts. Form deviations, possibly due to residual stress, have only been observed on the thinnest wall, which is also the part with the highest measured thermal gradients. Other form deviations were due to roughness