Uncertainties Induced by Processing Parameter Variation in Selective Laser Melting of Ti6Al4V Revealed by In-Situ X-ray Imaging

• Published in: Materials Vol. 15; no. 2; p. 530
• Main Authors: Young, Zachary A, Coday, Meelap M, Guo, Qilin, Qu, Minglei, Hojjatzadeh, S Mohammad H, Escano, Luis I, Fezzaa, Kamel, Sun, Tao, Chen, Lianyi
• Format: Journal Article
• Language: English
• Published: Switzerland MDPI AG 11-01-2022; MDPI
• Subjects: additive manufacturing; Geometry; Laser beam melting; laser powder bed fusion; Laser processing; Lasers; Manufacturing; MATERIALS SCIENCE; melt pool dynamics; Parameter identification; Process parameters; quality uncertainty; Selective laser melting; spatter; Thickness; Titanium alloys; Titanium base alloys; Uncertainty; X ray imagery; Canada; selective laser melting; spatter; additive manufacturing; melt pool dynamics; laser powder bed fusion; quality uncertainty
• ISSN: 1996-1944; 1996-1944
• DOI: 10.3390/ma15020530

Selective laser melting (SLM) additive manufacturing (AM) exhibits uncertainties, where variations in build quality are present despite utilizing the same optimized processing parameters. In this work, we identify the sources of uncertainty in SLM process by in-situ characterization of SLM dynamics induced by small variations in processing parameters. We show that variations in the laser beam size, laser power, laser scan speed, and powder layer thickness result in significant variations in the depression zone, melt pool, and spatter behavior. On average, a small deviation of only ~5% from the optimized/reference laser processing parameter resulted in a ~10% or greater change in the depression zone and melt pool geometries. For spatter dynamics, small variation (10 μm, 11%) of the laser beam size could lead to over 40% change in the overall volume of the spatter generated. The responses of the SLM dynamics to small variations of processing parameters revealed in this work are useful for understanding the process uncertainties in the SLM process.