Pore elimination mechanisms during 3D printing of metals
Laser powder bed fusion (LPBF) is a 3D printing technology that can print metal parts with complex geometries without the design constraints of traditional manufacturing routes. However, the parts printed by LPBF normally contain many more pores than those made by conventional methods, which severel...
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| Published in: | Nature communications Vol. 10; no. 1; pp. 3088 - 8 |
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| Main Authors: | , , , , , , , , , , , , |
| Format: | Journal Article |
| Language: | English |
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Nature Publishing Group UK
12-07-2019
Nature Publishing Group Nature Portfolio |
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| Abstract | Laser powder bed fusion (LPBF) is a 3D printing technology that can print metal parts with complex geometries without the design constraints of traditional manufacturing routes. However, the parts printed by LPBF normally contain many more pores than those made by conventional methods, which severely deteriorates their properties. Here, by combining in-situ high-speed high-resolution synchrotron x-ray imaging experiments and multi-physics modeling, we unveil the dynamics and mechanisms of pore motion and elimination in the LPBF process. We find that the high thermocapillary force, induced by the high temperature gradient in the laser interaction region, can rapidly eliminate pores from the melt pool during the LPBF process. The thermocapillary force driven pore elimination mechanism revealed here may guide the development of 3D printing approaches to achieve pore-free 3D printing of metals.
3D printing pore-free complex metal parts remains a challenge. Here, the authors combine in-situ imaging and simulations to show thermocapillary force can eliminate pores from the melt pool during a laser powder bed fusion process. |
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| AbstractList | Laser powder bed fusion (LPBF) is a 3D printing technology that can print metal parts with complex geometries without the design constraints of traditional manufacturing routes. However, the parts printed by LPBF normally contain many more pores than those made by conventional methods, which severely deteriorates their properties. Here, by combining in-situ high-speed high-resolution synchrotron x-ray imaging experiments and multi-physics modeling, we unveil the dynamics and mechanisms of pore motion and elimination in the LPBF process. We find that the high thermocapillary force, induced by the high temperature gradient in the laser interaction region, can rapidly eliminate pores from the melt pool during the LPBF process. The thermocapillary force driven pore elimination mechanism revealed here may guide the development of 3D printing approaches to achieve pore-free 3D printing of metals. Laser powder bed fusion (LPBF) is a 3D printing technology that can print metal parts with complex geometries without the design constraints of traditional manufacturing routes. However, the parts printed by LPBF normally contain many more pores than those made by conventional methods, which severely deteriorates their properties. Here, by combining in-situ high-speed high-resolution synchrotron x-ray imaging experiments and multi-physics modeling, we unveil the dynamics and mechanisms of pore motion and elimination in the LPBF process. We find that the high thermocapillary force, induced by the high temperature gradient in the laser interaction region, can rapidly eliminate pores from the melt pool during the LPBF process. The thermocapillary force driven pore elimination mechanism revealed here may guide the development of 3D printing approaches to achieve pore-free 3D printing of metals. 3D printing pore-free complex metal parts remains a challenge. Here, the authors combine in-situ imaging and simulations to show thermocapillary force can eliminate pores from the melt pool during a laser powder bed fusion process. 3D printing pore-free complex metal parts remains a challenge. Here, the authors combine in-situ imaging and simulations to show thermocapillary force can eliminate pores from the melt pool during a laser powder bed fusion process. Abstract Laser powder bed fusion (LPBF) is a 3D printing technology that can print metal parts with complex geometries without the design constraints of traditional manufacturing routes. However, the parts printed by LPBF normally contain many more pores than those made by conventional methods, which severely deteriorates their properties. Here, by combining in-situ high-speed high-resolution synchrotron x-ray imaging experiments and multi-physics modeling, we unveil the dynamics and mechanisms of pore motion and elimination in the LPBF process. We find that the high thermocapillary force, induced by the high temperature gradient in the laser interaction region, can rapidly eliminate pores from the melt pool during the LPBF process. The thermocapillary force driven pore elimination mechanism revealed here may guide the development of 3D printing approaches to achieve pore-free 3D printing of metals. |
| ArticleNumber | 3088 |
| Author | Qu, Minglei Xiong, Lianghua Hojjatzadeh, S. Mohammad H. Fezzaa, Kamel Sun, Tao Yan, Wentao Everhart, Wes Escano, Luis I. Chen, Lianyi Zhao, Cang Xiao, Xianghui Parab, Niranjan D. Guo, Qilin |
| Author_xml | – sequence: 1 givenname: S. Mohammad H. orcidid: 0000-0003-2562-4824 surname: Hojjatzadeh fullname: Hojjatzadeh, S. Mohammad H. organization: Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Department of Materials Science and Engineering, Missouri University of Science and Technology – sequence: 2 givenname: Niranjan D. orcidid: 0000-0002-3215-1466 surname: Parab fullname: Parab, Niranjan D. organization: X-ray Science Division, Advanced Photon Source, Argonne National Laboratory – sequence: 3 givenname: Wentao orcidid: 0000-0001-8480-6375 surname: Yan fullname: Yan, Wentao organization: Department of Mechanical Engineering, National University of Singapore – sequence: 4 givenname: Qilin orcidid: 0000-0003-1779-8875 surname: Guo fullname: Guo, Qilin organization: Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Department of Materials Science and Engineering, Missouri University of Science and Technology – sequence: 5 givenname: Lianghua orcidid: 0000-0001-5323-6525 surname: Xiong fullname: Xiong, Lianghua organization: Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Department of Materials Science and Engineering, Missouri University of Science and Technology – sequence: 6 givenname: Cang orcidid: 0000-0002-2464-2409 surname: Zhao fullname: Zhao, Cang organization: X-ray Science Division, Advanced Photon Source, Argonne National Laboratory – sequence: 7 givenname: Minglei orcidid: 0000-0001-9166-6702 surname: Qu fullname: Qu, Minglei organization: Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Department of Materials Science and Engineering, Missouri University of Science and Technology – sequence: 8 givenname: Luis I. surname: Escano fullname: Escano, Luis I. organization: Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology – sequence: 9 givenname: Xianghui orcidid: 0000-0002-7142-3452 surname: Xiao fullname: Xiao, Xianghui organization: X-ray Science Division, Advanced Photon Source, Argonne National Laboratory – sequence: 10 givenname: Kamel orcidid: 0000-0001-6135-8450 surname: Fezzaa fullname: Fezzaa, Kamel organization: X-ray Science Division, Advanced Photon Source, Argonne National Laboratory – sequence: 11 givenname: Wes orcidid: 0000-0001-6253-5527 surname: Everhart fullname: Everhart, Wes organization: Department of Energy’s Kansas City National Security Campus Managed by Honeywell FM&T – sequence: 12 givenname: Tao orcidid: 0000-0002-4881-9774 surname: Sun fullname: Sun, Tao email: taosun@aps.anl.gov organization: X-ray Science Division, Advanced Photon Source, Argonne National Laboratory – sequence: 13 givenname: Lianyi orcidid: 0000-0003-3720-398X surname: Chen fullname: Chen, Lianyi email: chenliany@mst.edu organization: Department of Mechanical and Aerospace Engineering, Missouri University of Science and Technology, Department of Materials Science and Engineering, Missouri University of Science and Technology |
| BackLink | https://www.ncbi.nlm.nih.gov/pubmed/31300676$$D View this record in MEDLINE/PubMed https://www.osti.gov/servlets/purl/1572905$$D View this record in Osti.gov |
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| References | DebRoy (CR1) 2018; 92 Calta (CR14) 2018; 89 Leuders (CR5) 2013; 48 Gu, Meiners, Wissenbach, Poprawe (CR2) 2012; 57 Leung (CR11) 2018; 9 Abràmoff, Magalhães, Ram (CR30) 2004; 11 Wang, Liu, Ohnuma, Kainuma, Ishida (CR19) 2002; 297 Pfefferkorn, Duffie, Li, Vadali, Ma (CR24) 2013; 62 Weingarten (CR9) 2015; 221 Young, Goldstein, Block (CR34) 1959; 6 Tammas-Williams, Withers, Todd, Prangnell (CR12) 2016; 122 Matsunawa, Kim, Seto, Mizutani, Katayama (CR13) 1998; 10 Zhao (CR17) 2017; 7 Yan (CR22) 2017; 134 Lin, Tsuchiya, Fan (CR29) 1998; 44 Chen, Shen, Tsai (CR18) 2016; 139 Chen (CR20) 2014; 5 Huang, Warnken, Gebelin, Strangwood, Reed (CR26) 2012; 60 Todeschini, Champier, Samuel (CR27) 1992; 27 Tang, Pistorius (CR8) 2017; 94 Martin (CR3) 2017; 549 Khairallah, Anderson, Rubenchik, King (CR7) 2016; 108 Guo (CR16) 2018; 151 Sames, List, Pannala, Dehoff, Babu (CR4) 2016; 61 Gürsoy, De Carlo, Xiao, Jacobsen (CR31) 2014; 21 Parab (CR15) 2018; 25 Yan (CR23) 2018; 61 Delnoij, Lammers, Kuipers, Van Swaaij (CR33) 1997; 52 Yan (CR21) 2016; 115 Nicolas (CR6) 2017; 5 Kobatake, Brillo, Schmitz, Pichon (CR35) 2015; 50 Zuber (CR28) 1961; 2 Clift, Grace, Weber (CR10) 1978 Vilar (CR25) 1999; 11 Manica, Klaseboer, Chan (CR32) 2016; 235 31570717 - Nat Commun. 2019 Sep 30;10(1):4506 NP Calta (10973_CR14) 2018; 89 CP Wang (10973_CR19) 2002; 297 R Vilar (10973_CR25) 1999; 11 D Gürsoy (10973_CR31) 2014; 21 W Yan (10973_CR23) 2018; 61 Q Guo (10973_CR16) 2018; 151 TJ Lin (10973_CR29) 1998; 44 E Delnoij (10973_CR33) 1997; 52 S Tammas-Williams (10973_CR12) 2016; 122 DD Gu (10973_CR2) 2012; 57 W Yan (10973_CR21) 2016; 115 JL Huang (10973_CR26) 2012; 60 C Zhao (10973_CR17) 2017; 7 H Kobatake (10973_CR35) 2015; 50 R Clift (10973_CR10) 1978 C Chen (10973_CR18) 2016; 139 NO Young (10973_CR34) 1959; 6 S Leuders (10973_CR5) 2013; 48 CLA Leung (10973_CR11) 2018; 9 A Nicolas (10973_CR6) 2017; 5 M Tang (10973_CR8) 2017; 94 WJ Sames (10973_CR4) 2016; 61 MD Abràmoff (10973_CR30) 2004; 11 A Matsunawa (10973_CR13) 1998; 10 JH Martin (10973_CR3) 2017; 549 C Weingarten (10973_CR9) 2015; 221 L-Y Chen (10973_CR20) 2014; 5 N Zuber (10973_CR28) 1961; 2 SA Khairallah (10973_CR7) 2016; 108 FE Pfefferkorn (10973_CR24) 2013; 62 ND Parab (10973_CR15) 2018; 25 W Yan (10973_CR22) 2017; 134 P Todeschini (10973_CR27) 1992; 27 T DebRoy (10973_CR1) 2018; 92 R Manica (10973_CR32) 2016; 235 |
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| Snippet | Laser powder bed fusion (LPBF) is a 3D printing technology that can print metal parts with complex geometries without the design constraints of traditional... Abstract Laser powder bed fusion (LPBF) is a 3D printing technology that can print metal parts with complex geometries without the design constraints of... 3D printing pore-free complex metal parts remains a challenge. Here, the authors combine in-situ imaging and simulations to show thermocapillary force can... |
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| SubjectTerms | 3-D printers 639/301/1023/1026 639/301/930/1032 Coordination compounds High temperature Humanities and Social Sciences Image resolution MATERIALS SCIENCE Melting Metals multidisciplinary Pores Powder Powder beds Printing Science Science (multidisciplinary) Synchrotron radiation Temperature gradients Thermocapillary force Three dimensional printing X ray imagery |
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