In situ alloying: investigation of the melt pool stability during powder bed fusion of metals using a laser beam in a novel experimental set-up

Wimmer, Andreas; Hofstaetter, Fabian; Jugert, Constantin; Wudy, Katrin; Zaeh, Michael F.

doi:10.1007/s40964-021-00233-y

Cited by 8 publications

(3 citation statements)

References 21 publications

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“…The beam was expanded by a collimator (D50-F200, IPG, Burbach, Germany) and was then guided through the scanning system for area irradiation (intelliSCAN III30, Scanlab, München, Germany) and beam waist variation (varioSCAN de40i, Scanlab, München, Germany). A more detailed description of the test bench can be found in the work of [ 28 ]. The process monitoring system consisted of an off-axis thermographic camera (TC) and an off-axis high-speed camera (HSC2).…”

Section: Materials and Methodsmentioning

confidence: 99%

Methodology to Determine Melt Pool Anomalies in Powder Bed Fusion of Metals Using a Laser Beam by Means of Process Monitoring and Sensor Data Fusion

et al. 2022

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Additive manufacturing, in particular the powder bed fusion of metals using a laser beam, has a wide range of possible technical applications. Especially for safety-critical applications, a quality assurance of the components is indispensable. However, time-consuming and costly quality assurance measures, such as computer tomography, represent a barrier for further industrial spreading. For this reason, alternative methods for process anomaly detection using process monitoring systems have been developed. However, the defect detection quality of current methods is limited, as single monitoring systems only detect specific process anomalies. Therefore, a new methodology to evaluate the data of multiple monitoring systems is derived using sensor data fusion. Focus was placed on the causes and the appearance of defects in different monitoring systems (photodiodes, on- and off-axis high-speed cameras, and thermography). Based on this, indicators representing characteristics of the process were developed to reduce the data. Finally, deterministic models for the data fusion within a monitoring system and between the monitoring systems were developed. The result was a defect detection of up to 92% of the melt track defects. The methodology was thus able to determine process anomalies and to evaluate the suitability of a specific process monitoring system for the defect detection.

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Section: Materials and Methodsmentioning

confidence: 99%

Methodology to Determine Melt Pool Anomalies in Powder Bed Fusion of Metals Using a Laser Beam by Means of Process Monitoring and Sensor Data Fusion

et al. 2022

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“…The simulation model was validated with the experimental data of a single-track experiment using the novel test bench [10]. Following the usual practice, the geometrical information of the molten pool was used to quantify the accuracy of the simulation results on a global scale [21,38,39].…”

Section: Methodsmentioning

confidence: 99%

“…As the surface tension of AlSi10Mg is characterized by almost half the surface tension of 316L and is less sensitive to temperature variations [8,9], the Marangoni effects are significantly reduced with a high impact on the melt pool dynamics. Wimmer et al [10] showed an increasing melt pool stability with increasing Al content, which was attributed to the Marangoni convection.…”

Section: Introduction and State Of The Artmentioning

confidence: 96%

Experimental and Numerical Investigations of In Situ Alloying during Powder Bed Fusion of Metals Using a Laser Beam

Wimmer

Yalvac

Zoeller

et al. 2021

Metals

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Powder Bed Fusion of Metals using a Laser Beam (PBF-LB/M) is increasingly utilized for the fabrication of complex parts in various industrial sectors. Enabling a robust and reproducible manufacturing process is one of the main goals in view of the future success of PBF-LB/M. To meet these challenges, alloys that are specifically adapted to the process are required. This paper demonstrates the successful interplay of simulation studies with experimental data to analyze the basic phenomena of in situ alloying. The meshless Smoothed-Particle Hydrodynamics (SPH) method was employed for the numerical simulation of two-component powder systems considering both thermodynamics and fluid mechanics in the solid and the melt phase. The simulation results for the in situ alloying of stainless steel 316L blended with the aluminum alloy AlSi10Mg were enriched and validated with the data from a novel experimental test bench. The combination of both approaches can enhance the understanding of the process for in situ alloying. Therefore, future investigations of the PBF-LB/M process with multi-component powder systems can benefit from detailed numerical studies using SPH.

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Influence of Powder Chemistry on Additive Manufacturing

2024

Metallic Powders for Additive Manufacturing

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In situ alloying: investigation of the melt pool stability during powder bed fusion of metals using a laser beam in a novel experimental set-up

Cited by 8 publications

References 21 publications

Methodology to Determine Melt Pool Anomalies in Powder Bed Fusion of Metals Using a Laser Beam by Means of Process Monitoring and Sensor Data Fusion

Methodology to Determine Melt Pool Anomalies in Powder Bed Fusion of Metals Using a Laser Beam by Means of Process Monitoring and Sensor Data Fusion

Experimental and Numerical Investigations of In Situ Alloying during Powder Bed Fusion of Metals Using a Laser Beam

Influence of Powder Chemistry on Additive Manufacturing

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