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

IF 4.2 Q2 ENGINEERING, MANUFACTURING

Additive manufacturing letters Pub Date : 2024-09-05 DOI:10.1016/j.addlet.2024.100239

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

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Abstract

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.

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利用高速 X 射线成像对电子束熔化过程中的缺陷形成和消除动态进行现场表征

电子束熔融（EBM），又称电子束粉末床熔融（EB-PBF），是一种金属增材制造（AM）技术，可以制造出通过传统制造途径和其他AM技术难以实现、效率低下或无法制造的金属零件。然而，对 EBM 中电子束与物质相互作用动力学的全面了解仍然遥遥无期，这对 EBM 技术的开发和应用构成了障碍。在此，我们报告了 EBM 中孔隙形成、孔隙消除和裂纹消除的动力学和机制。我们观察到孔隙形成的三种机制：(1) 原料粉末形成孔隙；(2) 预先存在的缺陷形成孔隙；(3) 凝固前沿捕获孔隙。发现了一种孔隙消除机制：金属蒸汽冷凝导致的孔隙消除，这是 EBM 独有的机制。发现了一种裂纹消除机制：通过重熔消除裂纹。这些结果将加深人们对 EBM 中缺陷形成和演变机制的理解，并可能启发人们发明有效的方法来减轻和控制 EBM 中的缺陷（孔隙率和裂纹）。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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