[논문]Controlling interdependent meso-nanosecond dynamics and defect generation in metal 3D printing

Khairallah, Saad A.; Martin, Aiden A.; Lee, Jonathan R. I.; Guss, Gabe; Calta, Nicholas P.; Hammons, Joshua A.; Nielsen, Michael H.; Chaput, Kevin; Schwalbach, Edwin; Shah, Megna N.; Chapman, Michael G.; Willey, Trevor M.; Rubenchik, Alexander M.; Anderson, Andrew T.; Wang, Y. Morris; Matthews, Manyalibo J.; King, Wayne E.

doi:10.1126/science.aay7830

[해외논문] Controlling interdependent meso-nanosecond dynamics and defect generation in metal 3D printing

Science, v.368 no.6491 = no.6491, 2020년, pp.660 - 665

Khairallah, Saad A. (Lawrence Livermore National Laboratory, Livermore, CA 94550, USA.) , Martin, Aiden A. (Lawrence Livermore National Laboratory, Livermore, CA 94550, USA.) , Lee, Jonathan R. I. (Lawrence Livermore National Laboratory, Livermore, CA 94550, USA.) , Guss, Gabe (Lawrence Livermore National Laboratory, Livermore, CA 94550, USA.) , Calta, Nicholas P. (Lawrence Livermore National Laboratory, Livermore, CA 94550, USA.) , Hammons, Joshua A. (Lawrence Livermore National Laboratory, Livermore, CA 94550, USA.) , Nielsen, Michael H. (Lawrence Livermore National Laboratory, Livermore, CA 94550, USA.) , Chaput, Kevin (Air Force Research Laboratory, Wright-Patterson Air Force Base, OH 45433, USA.) , Schwalbach, Edwin (Air Force Research Laboratory, Wright-Patterson Air Force Base, OH 45433, USA.) , Shah, Megna N. (Air Force Research Laboratory, Wright-Patterson Air Force Base, OH 45433, USA.) , Chapman, Michael G. (Air Force Research Laboratory, Wright-Patterson Air Force Base, OH 45433, USA.) , Willey, Trevor M. (Lawrence Livermore National Laboratory, Livermore, CA 94550, USA.) , Rubenchik, Alexander M. (Lawrence Livermore National Laboratory, Livermore, CA 94550, USA.) , Anderson, Andrew T. (Lawrence Livermore National Laboratory, Livermore, CA 94550, USA) , Wang, Y. Morris , Matthews, Manyalibo J. , King, Wayne E.

Abstract ▼ AI-Helper

Circumventing spatterLaser powder bed fusion is an additive manufacturing technique that laser-melts powder layer by layer to build a three-dimensional (3D) part. Khairallah et al. used experiments and a multiphysics model to determine the origin of the melt spatter and defect formation that degrade the properties of built parts (see the Perspective by Polonsky and Pollock). Informed modulation of laser power is important to avoid disturbing the powder bed and creating laser shadowing. This reduces pore formations and leads to more uniform properties of 3D-printed parts.Science, this issue p. 660; see also p. 583State-of-the-art metal 3D printers promise to revolutionize manufacturing, yet they have not reached optimal operational reliability. The challenge is to control complex laser–powder–melt pool interdependency (dependent upon each other) dynamics. We used high-fidelity simulations, coupled with synchrotron experiments, to capture fast multitransient dynamics at the meso-nanosecond scale and discovered new spatter-induced defect formation mechanisms that depend on the scan strategy and a competition between laser shadowing and expulsion. We derived criteria to stabilize the melt pool dynamics and minimize defects. This will help improve build reliability.

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