Types of spatter and their features and formation mechanisms in laser powder bed fusion additive manufacturing process

Young, Zachary A.; Guo, Qilin; Parab, Niranjan D.; Zhao, Cang; Qu, Minglei; Escano, Luis I.; Fezzaa, Kamel; Everhart, Wes; Sun, Tao; Chen, Lianyi

doi:10.1016/j.addma.2020.101438

Cited by 91 publications

(69 citation statements)

References 28 publications

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“…The number of such particles, as shown by microscopic images, increases with the successive cycles of using the powder. Such particles can also be formed in the LPBF process as a type of spatter, in this case by collisions between metallic jet spatter and solid spatter [ 25 ].…”

Section: Resultsmentioning

confidence: 99%

Evaluation of Inconel 718 Metallic Powder to Optimize the Reuse of Powder and to Improve the Performance and Sustainability of the Laser Powder Bed Fusion (LPBF) Process

et al. 2021

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In this paper, a detailed assessment of Inconel 718 powder, with varying degrees of degradation due to repeated use in the Laser Powder Bed Fusion (LPBF) process, has been undertaken. Four states of IN718 powder (virgin, used, overflow and spatter) were characterized in terms of their morphology, flowability and physico-chemical properties. Studies showed that used and overflow powders were almost identical. The fine particle-size distribution of the virgin powder, in which 50% of particles were found to be below the nominal particle-size distribution (PSD), was recognized as the main reason for its lower flowability and the main cause of the differentiation between virgin, used and overflow powders. Only spatter powder was found to be degraded enough to preclude its direct LPBF reuse. The oxygen content in the spatter powder exceeded the limit value for IN718 by 290 ppm, and aluminum oxide spots were found on the spatter particles surfaces. Laser absorption analysis showed 10 pp higher laser absorption compared to the other powders. The results of evaluation showed that IN718 powder is resistant to multiple uses in the LPBF process. Due to the low degradation rate of IN718 powder, overflow powder can be re-enabled for multiple uses with a proper recycling strategy.

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Section: Resultsmentioning

confidence: 99%

Evaluation of Inconel 718 Metallic Powder to Optimize the Reuse of Powder and to Improve the Performance and Sustainability of the Laser Powder Bed Fusion (LPBF) Process

et al. 2021

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“…The spattered metal subsequently cool down forming particles of varying sizes depending on the duration of the condensation process. These spatter formations are not unique to Co-Cr-Mo and are widely observed in a range of materials processed using powder bed fusion as summarised by Young et al [ 91 ]. Although some spatters are observed, these are not extensive and can be seen to not obstruct the overall porous architecture being generated.…”

Section: Resultsmentioning

confidence: 98%

3D Printed Cobalt-Chromium-Molybdenum Porous Superalloy with Superior Antiviral Activity

Arjunan

Robinson

Baroutaji

et al. 2021

IJMS

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COVID-19 pandemic and associated supply-chain disruptions emphasise the requirement for antimicrobial materials for on-demand manufacturing. Besides aerosol transmission, SARS-CoV-2 is also propagated through contact with virus-contaminated surfaces. As such, the development of effective biofunctional materials that can inactivate SARS-CoV-2 is critical for pandemic preparedness. Such materials will enable the rational development of antiviral devices with prolonged serviceability, reducing the environmental burden of disposable alternatives. This research reveals the novel use of Laser Powder Bed Fusion (LPBF) to 3D print porous Cobalt-Chromium-Molybdenum (Co-Cr-Mo) superalloy with potent antiviral activity (100% viral inactivation in 30 min). The porous material was rationally conceived using a multi-objective surrogate model featuring track thickness (tt) and pore diameter (ϕd) as responses. The regression analysis found the most significant parameters for Co-Cr-Mo track formation to be the interaction effects of scanning rate (Vs) and laser power (Pl) in the order PlVs>Vs>Pl. Contrastively, the pore diameter was found to be primarily driven by the hatch spacing (Sh). The study is the first to demonstrate the superior antiviral properties of 3D printed Co-Cr-Mo superalloy against an enveloped virus used as biosafe viral model of SARS-CoV-2. The material significantly outperforms the viral inactivation time of other broadly used antiviral metals such as copper and silver, as the material’s viral inactivation time was from 5 h to 30 min. As such, the study goes beyond the current state-of-the-art in antiviral alloys to provide extra protection to combat the SARS-CoV-2 viral spread. The evolving nature of the COVID-19 pandemic brings new and unpredictable challenges where on-demand 3D printing of antiviral materials can achieve rapid solutions while reducing the environmental impact of disposable devices.

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“…These spatter formations are not unique to Co-Cr-Mo and are widely observed in a range of materials processed using powder bed fusion as summarised by Young et al . [52]. Although some spatters are observed, these are not extensive and can be seen to not obstruct the overall porous architecture being generated.…”

Section: Resultsmentioning

confidence: 99%

“…The resulting track thickness and pore dimensions were characterised using scanning electron microscopy (SEM). EVO 50 SEM produced by Zeiss that uses an incident electron beam to interact with the printed sample to generate backscattered and secondary electrons to create an image of the porous sample is used [48][49][50][51][52].…”

Section: Laser Powder Bed Fusion (Lpbf)mentioning

confidence: 99%

3D printed cobalt-chromium-molybdenum porous superalloy with superior antiviral activity

Arjunan

Robinson

Baroutaji

et al. 2021

Preprint

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COVID-19 pandemic and associated supply-chain disruptions emphasise the requirement for antimicrobial materials for on-demand manufacturing. Besides aerosol transmission, SARS-CoV-2 is also propagated through contact with virus-contaminated surfaces. As such, the development of effective biofunctional materials that can inactivate SARS-CoV-2 is critical for pandemic preparedness. Such materials will enable the rational development of antiviral devices with prolonged serviceability, reducing the environmental burden of disposable alternatives. This research reveals the novel use of Laser Powder Bed Fusion (LPBF) to 3D print porous Cobalt-Chromium-Molybdenum (Co-Cr-Mo) superalloy with potent antiviral activity (100% viral inactivation in 30 mins). The porous material was rationally conceived using a multi-objective surrogate model featuring track thickness (tt) and pore diameter (ϕd) as responses. The regression analysis found the most significant parameters for Co-Cr-Mo track formation to be the interaction effects of scanning rate (Vs) and laser power (Pl) in the order PlVs>Vs>Pl. Contrastively, the pore diameter was found to be primarily driven by the hatch spacing (Sh). The study is the first to demonstrate the superior antiviral properties of 3D printed Co-Cr-Mo superalloy against an enveloped virus used as biosafe viral model of SARS CoV 2. The material significantly outperforms the viral inactivation time of other broadly used antiviral metals such as copper and silver from 5 hours to 30 minutes. As such, the study goes beyond the current state-of-the-art in antiviral alloys to provide extra protection to combat the SARS-COV-2 viral spread. The evolving nature of the COVID-19 pandemic brings new and unpredictable challenges where on-demand 3D printing of antiviral materials can achieve rapid solutions while reducing the environmental impact of disposable devices.

show abstract

Types of spatter and their features and formation mechanisms in laser powder bed fusion additive manufacturing process

Cited by 91 publications

References 28 publications

Evaluation of Inconel 718 Metallic Powder to Optimize the Reuse of Powder and to Improve the Performance and Sustainability of the Laser Powder Bed Fusion (LPBF) Process

Evaluation of Inconel 718 Metallic Powder to Optimize the Reuse of Powder and to Improve the Performance and Sustainability of the Laser Powder Bed Fusion (LPBF) Process

3D Printed Cobalt-Chromium-Molybdenum Porous Superalloy with Superior Antiviral Activity

3D printed cobalt-chromium-molybdenum porous superalloy with superior antiviral activity

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