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Synchrotron X-ray imaging of directed energy deposition additive manufacturing of titanium alloy Ti-6242

DOI: 10.1016/j.addma.2021.101969 DOI Help

Authors: Yunhui Chen (University College London; Research Complex at Harwell) , Samuel J. Clark (University College London; Research Complex at Harwell) , Lorna Sinclair (University College London; Research Complex at Harwell) , Chu Lun Alex Leung (University College London; Research Complex at Harwell) , Sebastian Marussi (University College London; Research Complex at Harwell) , Thomas Connolley (Diamond Light Source) , Robert C. Atwood (Diamond Light Source) , Gavin J. Baxter (Rolls-Royce plc) , Martyn A. Jones (Rolls-Royce plc) , Iain Todd (The University of Sheffield) , Peter D. Lee (University College London; Research Complex at Harwell)
Co-authored by industrial partner: Yes

Type: Journal Paper
Journal: Additive Manufacturing , VOL 92

State: Published (Approved)
Published: March 2021
Diamond Proposal Number(s): 20096

Abstract: Directed Energy Deposition Additive Manufacturing (DED-AM) is transformative for the production of larger, geometrically complex metallic components. However, the mechanical properties of titanium alloy DED-AM components do not always reach their full potential due to microstructural features including porosity and regions of lack of fusion. Using in situ and operando synchrotron X-ray imaging we gain insights into key laser-matter interaction and microstructural feature formation mechanisms during DED-AM of Ti-6242. Analysis of the process conditions reveals that laser power is dominant for build efficiency while higher traverse speed can effectively reduce lack of fusion regions. We also elucidate the mechanisms underlying several physical phenomena occurring during the deposition of titanium alloys, including the formation of a saddle-shaped melt pool and pore pushing. The findings of this work clarify the transient kinetics behind the DED-AM of titanium alloys and can be used as a guide for optimising industrial additive manufacturing processes.

Journal Keywords: Directed Energy Deposition; Synchrotron X-ray imaging; Laser Additive Manufacturing; Pore Formation

Diamond Keywords: Additive Manufacturing; Alloys

Subject Areas: Materials, Engineering

Instruments: I12-JEEP: Joint Engineering, Environmental and Processing

Discipline Tags:

Engineering & Technology Industrial Engineering Material Sciences Metallurgy

Technical Tags:

Imaging Tomography