Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing

Abstract The results of detailed experiments and finite element modeling of metal micro-droplet motion associated with metal additive manufacturing (AM) processes are presented. Ultra high speed imaging of melt pool dynamics reveals that the dominant mechanism leading to micro-droplet ejection in a...

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Autores principales:	Sonny Ly, Alexander M. Rubenchik, Saad A. Khairallah, Gabe Guss, Manyalibo J. Matthews
Formato:	article
Lenguaje:	EN
Publicado:	Nature Portfolio 2017
Materias:	Medicine R Science Q
Acceso en línea:	https://doaj.org/article/5ae7ecd6eb47456db35b3325bdb4e03f
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spelling	oai:doaj.org-article:5ae7ecd6eb47456db35b3325bdb4e03f2021-12-02T12:32:50ZMetal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing10.1038/s41598-017-04237-z2045-2322https://doaj.org/article/5ae7ecd6eb47456db35b3325bdb4e03f2017-06-01T00:00:00Zhttps://doi.org/10.1038/s41598-017-04237-zhttps://doaj.org/toc/2045-2322Abstract The results of detailed experiments and finite element modeling of metal micro-droplet motion associated with metal additive manufacturing (AM) processes are presented. Ultra high speed imaging of melt pool dynamics reveals that the dominant mechanism leading to micro-droplet ejection in a laser powder bed fusion AM is not from laser induced recoil pressure as is widely believed and found in laser welding processes, but rather from vapor driven entrainment of micro-particles by an ambient gas flow. The physics of droplet ejection under strong evaporative flow is described using simulations of the laser powder bed interactions to elucidate the experimental results. Hydrodynamic drag analysis is used to augment the single phase flow model and explain the entrainment phenomenon for 316 L stainless steel and Ti-6Al-4V powder layers. The relevance of vapor driven entrainment of metal micro-particles to similar fluid dynamic studies in other fields of science will be discussed.Sonny LyAlexander M. RubenchikSaad A. KhairallahGabe GussManyalibo J. MatthewsNature PortfolioarticleMedicineRScienceQENScientific Reports, Vol 7, Iss 1, Pp 1-12 (2017)
institution	DOAJ
collection	DOAJ
language	EN
topic	Medicine R Science Q
spellingShingle	Medicine R Science Q Sonny Ly Alexander M. Rubenchik Saad A. Khairallah Gabe Guss Manyalibo J. Matthews Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing
description	Abstract The results of detailed experiments and finite element modeling of metal micro-droplet motion associated with metal additive manufacturing (AM) processes are presented. Ultra high speed imaging of melt pool dynamics reveals that the dominant mechanism leading to micro-droplet ejection in a laser powder bed fusion AM is not from laser induced recoil pressure as is widely believed and found in laser welding processes, but rather from vapor driven entrainment of micro-particles by an ambient gas flow. The physics of droplet ejection under strong evaporative flow is described using simulations of the laser powder bed interactions to elucidate the experimental results. Hydrodynamic drag analysis is used to augment the single phase flow model and explain the entrainment phenomenon for 316 L stainless steel and Ti-6Al-4V powder layers. The relevance of vapor driven entrainment of metal micro-particles to similar fluid dynamic studies in other fields of science will be discussed.
format	article
author	Sonny Ly Alexander M. Rubenchik Saad A. Khairallah Gabe Guss Manyalibo J. Matthews
author_facet	Sonny Ly Alexander M. Rubenchik Saad A. Khairallah Gabe Guss Manyalibo J. Matthews
author_sort	Sonny Ly
title	Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing
title_short	Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing
title_full	Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing
title_fullStr	Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing
title_full_unstemmed	Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing
title_sort	metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing
publisher	Nature Portfolio
publishDate	2017
url	https://doaj.org/article/5ae7ecd6eb47456db35b3325bdb4e03f
work_keys_str_mv	AT sonnyly metalvapormicrojetcontrolsmaterialredistributioninlaserpowderbedfusionadditivemanufacturing AT alexandermrubenchik metalvapormicrojetcontrolsmaterialredistributioninlaserpowderbedfusionadditivemanufacturing AT saadakhairallah metalvapormicrojetcontrolsmaterialredistributioninlaserpowderbedfusionadditivemanufacturing AT gabeguss metalvapormicrojetcontrolsmaterialredistributioninlaserpowderbedfusionadditivemanufacturing AT manyalibojmatthews metalvapormicrojetcontrolsmaterialredistributioninlaserpowderbedfusionadditivemanufacturing
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Metal vapor micro-jet controls material redistribution in laser powder bed fusion additive manufacturing

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