In Situ Measurements of Melt-Pool Length and Cooling Rate During 3D Builds of the Metal AM-Bench Artifacts
Source abstract
Abstract
This work provides results and analysis of the in situ thermal measurement acquired during the 3D builds performed for the 2018 additive manufacturing benchmark tests. The objective is to provide context for post-process characterization of distortion, residual strain, and microstructure, which are reported elsewhere in this Journal, and to provide validation data for thermal models of the build process. Four bridge artifacts (75 mm long, 5 mm wide, 12.5 mm tall) are created in each of three builds using a commercial laser powder bed fusion system. The builds are performed using nickel super alloy 625 (IN625). High-speed infrared thermography performed during four of the builds is used to measure the melt-pool length and cooling rate within a select region. The temperature of the substrate and build volume is measured during the fifth build to provide data to establish the boundary conditions for thermal models.
Source: europepmc · Quality: candidate unverified · Source record ↗
Research context
OpenAlex topics: Additive Manufacturing Materials and Processes · Additive Manufacturing and 3D Printing Technologies · Welding Techniques and Residual Stresses
SciVX discovery tags are terminology-based. OpenAlex topics are source-provided classifications.
References (30)
Show source-provided references
1. Denlinger ER, Michaleris P (2017) Mitigation of distortion in large additive manufacturing parts. Proc Inst Mech Eng Part B J Eng Manuf 231(6):983–99310.1177/0954405415578580 ↗
2. Denlinger ER, Heigel JC, Michaleris P (2014) Residual stress and distortion modeling of electron beam direct manufacturing Ti–6Al–4V. Proc Inst Mech Eng Part B J Eng Manuf 229:0954405414539494
3. Dunbar AJ, Denlinger ER, Gouge MF, Michaleris P (2016) Experimental validation of finite element modeling for laser powder bed fusion deformation. Addit Manuf 12:108–12010.1016/j.addma.2016.08.003 ↗
4. Bagg SD, Sochalski-Kolbus LM, Bunn JR (2016) The effect of laser scan strategy on distortion and residual stresses of arches made with selective laser melting. In: ASPE/euspen 2016 summer topical meeting on dimensional accuracy and surface finish in additive manufacturing, June 27–30, 2016, Releigh, North Carolina, USA. http://toc.proceedings.com/47967webtoc.pdf
5. Strantza M et al (2018) Coupled experimental and computational study of residual stresses of additively manufactured Ti–6Al–4V components. Mater Lett 231:221–22410.1016/j.matlet.2018.07.141 ↗
6. David S, Vitek J (1989) Correlation between solidification parameters and weld microstructures. Int Mater Rev 34(1):213–24510.1179/imr.1989.34.1.213 ↗
7. Antonysamy AA, Meyer J, Prangnell P (2013) Effect of build geometry on the β-grain structure and texture in additive manufacture of Ti6Al4V by selective electron beam melting. Mater Charact 84:153–16810.1016/j.matchar.2013.07.012 ↗
8. Dehoff R et al (2015) Site specific control of crystallographic grain orientation through electron beam additive manufacturing. Mater Sci Technol 31(8):931–93810.1179/1743284714Y.0000000734 ↗
9. Kriczky DA, Irwin J, Reutzel EW, Michaleris P, Nassar AR, Craig J (2015) 3D spatial reconstruction of thermal characteristics in directed energy deposition through optical thermal imaging. J Mater Process Technol 221:172–18610.1016/j.jmatprotec.2015.02.021 ↗
10. Carroll BE, Palmer TA, Beese AM (2015) Anisotropic tensile behavior of Ti–6Al–4V components fabricated with directed energy deposition additive manufacturing. Acta Mater 87:309–32010.1016/j.actamat.2014.12.054 ↗
11. Bennett JL et al (2018) Cooling rate effect on tensile strength of laser deposited Inconel 718. Procedia Manuf 26:912–91910.1016/j.promfg.2018.07.118 ↗
12. Krauss H, Eschey C, Zaeh M (2012) Thermography for monitoring the selective laser melting process. Presented at the proceedings of the solid freeform fabrication symposium, pp 999–1014
13. Craeghs T, Clijsters S, Kruth J-P, Bechmann F, Ebert M-C (2012) Detection of process failures in layerwise laser melting with optical process monitoring. Phys Proc 39:753–75910.1016/j.phpro.2012.10.097 ↗
14. Heigel JC, Whitenton E (2018) Measurement of thermal processing variability in powder bed fusion. In: 2018 ASPE and Euspen summer topical meeting advancing precision in additive manufacturing, Berkeley, pp 242–274
15. Hooper PA (2018) Melt pool temperature and cooling rates in laser powder bed fusion. Addit Manuf 22:548–559
16. Lane B et al (2016) Thermographic measurements of the commercial laser powder bed fusion process at NIST. Rapid Prototyp J 22(5):778–78710.1108/RPJ-11-2015-0161 ↗
17. Arısoy YM, Criales LE, Özel T, Lane B, Moylan S, Donmez A (2017) Influence of scan strategy and process parameters on microstructure and its optimization in additively manufactured nickel alloy 625 via laser powder bed fusion. Int J Adv Manuf Technol 90(5–8):1393–141710.1007/s00170-016-9429-z ↗
18. Lane B, Heigel J, Ricker R et al (2020) Measurements of melt pool geometry and cooling rates of individual laser traces on IN625 bare plates. Integr Mater Manuf Innov. https://doi.org/10.1007/s40192-020-00169-110.1007/s40192-020-00169-1 ↗
19. Phan T et al (2019) Elastic strain and stress measurements and corresponding part deflections of 3D AM builds of 15-5 and IN625 AM-Bench artifacts using neutron diffraction, synchrotron X-ray diffraction, and mechanical measurements. Integr Mater Manuf Innov 8(3):318–33410.1007/s40192-019-00149-0 ↗
20. Stoudt M, Williams ME, Claggett S, Heigel JC, Levine LE (2019) Location-specific microstructure within 3D AM builds of 15-5 and IN625 AM-Bench artifacts. Integr Mater Manuf Innov. https://doi.org/10.1007/s40192-020-00172-610.1007/s40192-020-00172-6 ↗
21. Zhang F, Levine LE, Allen AJ et al (2019) Phase fraction and evolution of additively manufactured (AM) 15–5 stainless steel and inconel 625 AM-bench artifacts. Integr Mater Manuf Innov 8:362. https://doi.org/10.1007/s40192-019-00148-110.1007/s40192-019-00148-1 ↗
22. Heigel JC, Lane BM, Levine LE, Phan TQ, Whiting J (2019) Thermography of the metal bridge structures fabricated for the 2018 additive manufacturing benchmark test series. J Res Natl Inst Stand Technol 125:125005. https://doi.org/10.6028/jres.125.00510.6028/jres.125.005 ↗
23. Moylan S, Whitenton E, Lane B, Slotwinski J (2014) Infrared thermography for laser based powder bed fusion additive manufacturing processes. In: 40th annual review of progress in quantitative nondestructive evaluation AIP conference proceedings10.1063/1.4864956 ↗
24. Lane B, Whitenton E (Dec 2015) Calibration and measurement procedures for a high magnification thermal camera. National Institute of Standards and Technology, Gaithersburg, MD, NISTIR 809810.6028/NIST.IR.8098 ↗
25. Heigel J, Lane B (2017) The effect of powder on cooling rate and melt-pool length measurements using in situ thermographic techniques. In: Proceedings of the 2017 annual international SFF symposium
26. Montgomery C, Beuth J, Sheridan L, Klinbeil N (2015) Process mapping of Inconel 625 in laser powder bed additive manufacturing. Presented at the solid freeform fabrication symposium, Austin, pp 1195–1204
27. Vasinonta A, Beuth JL, Griffith M (2007) Process maps for predicting residual stress and melt-pool size in the laser-based fabrication of thin-walled structures. J Manuf Sci Eng 129(1):101–10910.1115/1.2335852 ↗
28. Heigel JC, Lane BL, Moylan SP (2016) Variation of emissivity with powder bed fusion build parameters. Presented at the solid freeform fabrication symposium, Austin, pp 1660–1669
29. Taylor BN, Kuyatt CE (1994) Guidelines for evaluating and expressing the uncertainty of NIST measurement results. NIST technical note 1297
30. Makino T, Kawasaki H, Kunitomo T (1982) Study of the radiative properties of heat resisting metals and alloys: (1st report, optical constants and emissivities of nickel, cobalt and chromium). Bull JSME 25(203):804–81110.1299/jsme1958.25.804 ↗