In-situ characterization of defect formation and elimination dynamics during electron beam melting using high-speed X-ray imaging

Jiandong Yuan; Luis I. Escano; Samuel J. Clark; Junye Huang; Ali Nabaa; Qilin Guo; Minglei Qu; Kamel Fezzaa; Lianyi Chen

Additive Manufacturing Letters (Dec 2024)

In-situ characterization of defect formation and elimination dynamics during electron beam melting using high-speed X-ray imaging

Jiandong Yuan,
Luis I. Escano,
Samuel J. Clark,
Junye Huang,
Ali Nabaa,
Qilin Guo,
Minglei Qu,
Kamel Fezzaa,
Lianyi Chen

Affiliations

Jiandong Yuan: Department of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA; Department of Materials Science and Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA
Luis I. Escano: Department of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA; Department of Materials Science and Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA
Samuel J. Clark: X-ray Science Division, Advanced Photon Source, Argonne National Laboratory, Lemont, IL 60439, USA
Junye Huang: Department of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA; Department of Materials Science and Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA
Ali Nabaa: Department of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA; Department of Materials Science and Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA
Qilin Guo: Department of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA; Department of Materials Science and Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA
Minglei Qu: Department of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA; Department of Materials Science and Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA
Kamel Fezzaa: X-ray Science Division, Advanced Photon Source, Argonne National Laboratory, Lemont, IL 60439, USA
Lianyi Chen: Department of Mechanical Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA; Department of Materials Science and Engineering, University of Wisconsin-Madison, Madison, WI 53706, USA; Corresponding author.

Journal volume & issue: Vol. 11
p. 100239

Abstract

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Electron beam melting (EBM), also known as electron beam powder bed fusion (EB-PBF), is a metal additive manufacturing (AM) technology that can make metal parts that are difficult, inefficient, or unachievable through conventional manufacturing routes and other AM technologies. However, a comprehensive understanding of the dynamics of electron beam-matter interactions in EBM remains elusive, which is a barrier for the development and adoption of EBM technology. Here, we report the dynamics and mechanisms of pore formation, pore elimination, and crack elimination in EBM. Three mechanisms of pore formation are observed: (1) pore formation from feedstock powders, (2) pore formation from pre-existing defects, and (3) pore captured by solidification front. One pore elimination mechanism is discovered: pore elimination due to metal vapor condensation, which is unique to EBM. One crack elimination mechanism is uncovered: crack elimination through remelting. These results will enhance the understanding of defect formation and evolution mechanisms in EBM and may inspire the invention of effective approaches to mitigate and control defects (porosity and cracks) in EBM.

Published in Additive Manufacturing Letters

ISSN: 2772-3690 (Online)
Publisher: Elsevier
Country of publisher: Netherlands
LCC subjects: Technology: Technology (General): Industrial engineering. Management engineering
Website: https://www.journals.elsevier.com/additive-manufacturing-letters/

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