研究目的
Understanding the melt flow behavior in the melt pool in laser metal additive manufacturing under both conduction-mode and depression-mode melting, for understanding the actual melt flow behavior and for developing and validating computational models.
研究成果
The full-field melt flow mapping approach reported here opens the way to study the melt flow dynamics under real additive manufacturing conditions. Our findings reported here are critical for not only understanding the laser additive manufacturing process and other laser processes, but also for developing reliable high-fidelity computational models.
研究不足
The technical and application constraints of the experiments include the challenge of characterizing the three-dimensional melt flow in real laser additive manufacturing condition, especially under laser powder bed fusion condition, due to the high laser scan speed and the small resulting melt pool. The discrepancies in flow prediction and the need for assumptions in simulations due to the unavailability of data and the complexity of the physics involved.
1：Experimental Design and Method Selection:
In-situ high-speed high-resolution x-ray imaging was used for direct observation of the melt pool dynamics from different views during laser scanning.
2：Sample Selection and Data Sources:
Two aluminum alloys, AlSi10Mg and Al-6061, were used for this study. The powder bed is composed of either AlSi10Mg or Al-6061 aluminum alloy, with the substrate material identical to the powders.
3：List of Experimental Equipment and Materials:
Synchrotron x-ray beam (Beamline 32-ID-B, Advanced Photon Source, Argonne National Laboratory), continuous-wave laser beam with a wavelength of 1070 ± 10 nm and a maximum output power of 520 W, tungsten micro-particles (with an average diameter of 5 μm) as flow tracers.
4：Experimental Procedures and Operational Workflow:
The laser beam scans perpendicular to the x-ray beam to get the longitudinal projection of the melt pool, and another where the laser scans parallel to the x-ray to get the transverse projection of the melt pool.
5：Data Analysis Methods:
The projectional speed of melt flow was calculated by dividing its displacement by its travelling time. The tracers’ movement was analyzed to reflect the liquid flow in the present experimental conditions.
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