1. Finding the limits of single-track deposition experiments: An experimental study of melt pool characterization in laser powder bed fusion
- Author
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Frieden Templeton William, Hinnebusch Shawn, Strayer Seth, To Albert, and Narra Sneha Prabha
- Subjects
Laser powder bed fusion ,Process window ,Melt pool geometry ,Interpass temperature ,Inconel 718 ,Materials of engineering and construction. Mechanics of materials ,TA401-492 - Abstract
This work identifies sources of error in melt pool characterization tests that are frequently employed to study processing parameters in laser powder bed fusion (L-PBF) additive manufacturing (AM). At an early stage in process parameter development, researchers typically characterize the shape of single, non-overlapping melt tracks formed with varying processing conditions such as laser power and scanning velocity. However, as L-PBF enters mainstream manufacturing, researchers must test the limits of these commonly relied-upon characterization experiments to avoid errors that could impact process development. Hence, this study expands on conventional methods by depositing single-tracks and overlapping multitracks on a powder layer at multiple interpass temperatures, thereby mimicking heat buildup during the manufacturing of a multilayer part. While single-track melt pool depth and width do not increase as a function of interpass temperature as expected, multitrack experiments demonstrate a clear gradient in both melt pool depth, width and bead height between the first and final tracks. This work quantitatively demonstrates that the setup of single-track characterization experiments has a notable impact on the process parameter development. Alternatively, multitrack experiments closely capture the deposition conditions and melt pool variability observed during multilayer part fabrication.
- Published
- 2023
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