| Literature DB >> 32029753 |
Vivek Thampy1, Anthony Y Fong2, Nicholas P Calta3, Jenny Wang3, Aiden A Martin3, Philip J Depond3, Andrew M Kiss2, Gabe Guss4, Qingfeng Xing5, Ryan T Ott5, Anthony van Buuren3, Michael F Toney2, Johanna Nelson Weker2, Matthew J Kramer5, Manyalibo J Matthews3, Christopher J Tassone2, Kevin H Stone6.
Abstract
Laser powder bed fusion (LPBF) is a method of additive manufacturing characterized by the rapid scanning of a high powered laser over a thin bed of metallic powder to create a single layer, which may then be built upon to form larger structures. Much of the melting, resolidification, and subsequent cooling take place at much higher rates and with much higher thermal gradients than in traditional metallurgical processes, with much of this occurring below the surface. We have used in situ high speed X-ray diffraction to extract subsurface cooling rates following resolidification from the melt and above the β-transus in titanium alloy Ti-6Al-4V. We observe an inverse relationship with laser power and bulk cooling rates. The measured cooling rates are seen to correlate to the level of residual strain borne by the minority β-Ti phase with increased strain at slower cooling rates. The α-Ti phase shows a lattice contraction which is invariant with cooling rate. We also observe a broadening of the diffraction peaks which is greater for the β-Ti phase at slower cooling rates and a change in the relative phase fraction following LPBF. These results provide a direct measure of the subsurface thermal history and demonstrate its importance to the ultimate quality of additively manufactured materials.Entities:
Year: 2020 PMID: 32029753 PMCID: PMC7005153 DOI: 10.1038/s41598-020-58598-z
Source DB: PubMed Journal: Sci Rep ISSN: 2045-2322 Impact factor: 4.379
Figure 1Schematic of experimental geometry showing the relevant dimensions. The dimensions are not to scale.
Figure 2Diffraction data, collected at 500 Hz and 1 ms acquisition time per frame. Data is for build parameters of 200 W laser power, 144 mm/s scan speed, and X-ray spot size 50 μm below the powder substrate interface. (a) 2D Diffraction patterns 10 ms before (top), 4 ms after (middle), and 80 ms after (bottom) the laser scan. The insets show the positions of the laser relative to the X-ray probed region schematically at these times. (b) Corresponding azimuthally integrated intensities as a function of Q in blue, green and yellow respectively. (c) Integrated intensities plotted as a function of time on the vertical axis to show the evolution of the diffraction peaks during the LPBF process. The intensities for (a,c) are encoded by color with the scales indicated by the respective color bars.
Figure 3In situ cooling rates, calculated for data collected at 500 Hz frame rate and 1 ms acquisition time per frame. (a) Time evolution of scale factors of the α-Ti (blue circles) and β-Ti (orange diamonds) crystalline phases for laser power of 225 W and speed 144 mm/s. The drop in the α-Ti peak intensity coincides with the laser indicated by the dashed black line. Also, shown in the figure is the time period (τ) for which the phase fraction is mainly β-Ti. The solid lines are guides for the eye. (b) Lattice parameters of the α-Ti a- and c-parameters (blue diamonds and orange squares respectively) and β-Ti phase (green circles) as a function of time for same process parameters as (a). The c-lattice parameter of the α-Ti phase is divided by the approximate c/a ratio of 1.6 for the pristine material. The change in the lattice parameters of the β-Ti phase over τ is indicated as Δa. The lattice parameters for the α-Ti phase are not shown during τ because of the large uncertainties in this time range. (c) Cooling rates for a range of laser powers calculated from rate of lattice relaxation (blue circles), and β-Ti lifetime, τ, (orange diamonds).
Figure 4Correlating the cooling rates to changes in structural parameters and phase fraction of final build measured after the laser exposure. The change in (a) lattice parameters (both relative and absolute), (b) peak widths, and (c) phase fraction (α-Ti/β-Ti) are shown as a function of cooling rate calculated by taking the average of the cooling rates from the two methods outlined in the text.