{"title":"Impact of melt pool geometry variability on lack-of-fusion porosity and fatigue life in powder bed fusion-laser beam Ti–6Al–4V","authors":"","doi":"10.1016/j.addma.2024.104506","DOIUrl":null,"url":null,"abstract":"<div><div>Powder bed fusion-laser beam (PBF-LB) parts experience a significant decline in fatigue performance when process-induced defects are present. In this work, a decline in 4-point bend fatigue life was observed in PBF-LB Ti–6Al–4V coupons fabricated at constant power with increasing scanning velocity and which underwent subsequent stress relief and surface machining. Specifically, the presence of pores that resemble lack-of-fusion (LoF) and a decline in fatigue life were observed at scanning velocities lower than that expected from prior published work. It was hypothesized that this unexpected presence of LoF pores resulted from melt pool geometry variability that was not considered in prior work when the LoF criterion was implemented. Further, these pores can be small in size and infrequent in their occurrence when the melt pool geometry variability is not severe. Such sparse pores are challenging to characterize using conventional 2D characterization methods. This work leverages tall and narrow coupon geometry and high-resolution X-ray micro computed tomography (X-<span><math><mi>μ</mi></math></span>CT) to capture LoF porosity. The results show that a modified melt pool overlap-based LoF criterion considering melt pool geometry variability captures the unexpected occurrence of LoF pores observed in X-<span><math><mi>μ</mi></math></span>CT. In addition, the LoF percent metric displays a strongly negative correlation with fatigue performance. The insights from this work provide guidance on characterizing melt pool geometry variability across scan lines to systematically evaluate processing parameters that generate LoF pores, which, in turn, could lower fatigue performance.</div></div>","PeriodicalId":7172,"journal":{"name":"Additive manufacturing","volume":null,"pages":null},"PeriodicalIF":10.3000,"publicationDate":"2024-09-05","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Additive manufacturing","FirstCategoryId":"5","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S2214860424005529","RegionNum":1,"RegionCategory":"工程技术","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"ENGINEERING, MANUFACTURING","Score":null,"Total":0}
引用次数: 0
Abstract
Powder bed fusion-laser beam (PBF-LB) parts experience a significant decline in fatigue performance when process-induced defects are present. In this work, a decline in 4-point bend fatigue life was observed in PBF-LB Ti–6Al–4V coupons fabricated at constant power with increasing scanning velocity and which underwent subsequent stress relief and surface machining. Specifically, the presence of pores that resemble lack-of-fusion (LoF) and a decline in fatigue life were observed at scanning velocities lower than that expected from prior published work. It was hypothesized that this unexpected presence of LoF pores resulted from melt pool geometry variability that was not considered in prior work when the LoF criterion was implemented. Further, these pores can be small in size and infrequent in their occurrence when the melt pool geometry variability is not severe. Such sparse pores are challenging to characterize using conventional 2D characterization methods. This work leverages tall and narrow coupon geometry and high-resolution X-ray micro computed tomography (X-CT) to capture LoF porosity. The results show that a modified melt pool overlap-based LoF criterion considering melt pool geometry variability captures the unexpected occurrence of LoF pores observed in X-CT. In addition, the LoF percent metric displays a strongly negative correlation with fatigue performance. The insights from this work provide guidance on characterizing melt pool geometry variability across scan lines to systematically evaluate processing parameters that generate LoF pores, which, in turn, could lower fatigue performance.
期刊介绍:
Additive Manufacturing stands as a peer-reviewed journal dedicated to delivering high-quality research papers and reviews in the field of additive manufacturing, serving both academia and industry leaders. The journal's objective is to recognize the innovative essence of additive manufacturing and its diverse applications, providing a comprehensive overview of current developments and future prospects.
The transformative potential of additive manufacturing technologies in product design and manufacturing is poised to disrupt traditional approaches. In response to this paradigm shift, a distinctive and comprehensive publication outlet was essential. Additive Manufacturing fulfills this need, offering a platform for engineers, materials scientists, and practitioners across academia and various industries to document and share innovations in these evolving technologies.