Detection and Classification of Cracking Via Acoustic Emission During Laser-Melting Screening for Additive Manufacturing

IF 2.3 4区 材料科学 Q3 MATERIALS SCIENCE, MULTIDISCIPLINARY
JOM Pub Date : 2025-09-05 DOI:10.1007/s11837-025-07642-2
Evan B. Raeker, Nikhil Tulshibagwale, Kaitlyn M. Mullin, James D. Lamb, Tresa M. Pollock
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Abstract

Metal additive manufacturing provides opportunities for fabricating complex, high-performance parts. However, the processing demands of laser powder bed fusion have limited the availability of materials that are amenable to 3D printing, motivating development of new alloys that have low defect susceptibility. High-throughput screening tools are necessary to evaluate these new alloys and decrease prohibitive development costs. Acoustic emission sensing utilizing a piezoelectric sensor is investigated as a method for in situ crack detection during single-track laser melting experiments which are set to replicate laser powder bed fusion processing conditions. Two materials found to exhibit either solidification cracking (CMSX-4) or solid-state cracking (TZM) are examined, ultimately showing the experimental setup can detect individual solid-state cracking events but not solidification cracking events. Calibration of the sensor with ball-bearing drop tests down to 0.04 \(\upmu \)J provides a useful assessment of the sensitivity of the technique. Furthermore, the acoustic emission data can be used to determine relative differences in crack size with varying scanning parameters (laser power, scan speed) and gain insight into the crack initiation characteristics of the material.

Abstract Image

Abstract Image

增材制造激光熔化筛分中裂纹的声发射检测与分类
金属增材制造为制造复杂的高性能部件提供了机会。然而,激光粉末床融合的加工要求限制了适合3D打印的材料的可用性,这促使开发具有低缺陷敏感性的新合金。需要高通量筛选工具来评估这些新合金并降低过高的开发成本。在模拟激光粉末床熔合工艺条件的单轨迹激光熔化实验中,利用压电传感器进行声发射传感作为原位裂纹检测方法进行了研究。研究了两种材料的凝固开裂(CMSX-4)或固态开裂(TZM),最终表明实验装置可以检测到单个的固态开裂事件,但不能检测到凝固开裂事件。校准传感器与球轴承下降测试到0.04 \(\upmu \) J提供了一个有用的评估灵敏度的技术。此外,声发射数据可用于确定不同扫描参数(激光功率,扫描速度)下裂纹尺寸的相对差异,并深入了解材料的裂纹起裂特性。
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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来源期刊
JOM
JOM 工程技术-材料科学:综合
CiteScore
4.50
自引率
3.80%
发文量
540
审稿时长
2.8 months
期刊介绍: JOM is a technical journal devoted to exploring the many aspects of materials science and engineering. JOM reports scholarly work that explores the state-of-the-art processing, fabrication, design, and application of metals, ceramics, plastics, composites, and other materials. In pursuing this goal, JOM strives to balance the interests of the laboratory and the marketplace by reporting academic, industrial, and government-sponsored work from around the world.
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