MCF Summer Seminar

June 07, 2024

2:00 p.m. ET

124 Roberts Hall

Probing the Process Window Boundaries in Powder Bed Fusion-Laser Beam of Ti-6Al-4V, presented by Justin Miner

Parameter development for powder bed fusion - laser beam (PBF-LB) involves mapping the effects of process parameters such as laser power and scanning velocity on process outputs like porosity. Specifically, the process window is identified as combinations of process parameters that minimize defects such as Lack-of-Fusion (LoF), keyhole porosity, and balling. However, our work reveals that not all points within this process window are equal. Some methods of process mapping, such as utilizing part density and assuming defect boundaries follow lines of constant energy density, may not adequately identify defects because they do not capture the underlying phenomena. We further identify sparse LoF porosity using micro-CT, and identify its cause as melt pool geometry variability. Our findings highlight inherent process nuances and their impact on the defect boundaries defining the process window in PBF-LB. We present limitations within parameter development approaches and the importance of thorough evaluation of process parameters.

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