Sinclair, L;
Clark, SJ;
Chen, Y;
Marussi, S;
Shah, S;
Magdysyuk, OV;
Atwood, RC;
... Lee, PD; + view all
(2022)
Sinter formation during directed energy deposition of titanium alloy powders.
International Journal of Machine Tools and Manufacture
, 176
, Article 103887. 10.1016/j.ijmachtools.2022.103887.
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Abstract
During directed energy deposition (DED) additive manufacturing, powder agglomeration and sintering can occur outside of the melt pool when using titanium alloy powders. Using in situ synchrotron radiography we investigate the mechanisms by which sintering of Ti6242 powder occurs around the pool, performing a parametric study to determine the influence of laser power and stage traverse speed on sinter build-up. The results reveal that detrimental sinter can be reduced using a high laser power or increased stage traverse speed, although the latter also reduces deposition layer thickness. The mechanism of sinter formation during DED was determined to be in-flight heating of the powder particles in the laser beam. Calculations of particle heating under the processing conditions explored in this study confirm that powder particles can reasonably exceed 700 °C, the threshold for Ti surface oxide dissolution, and thus the powder is prone to sintering if not incorporated into the melt pool. The build-up of sinter powder layer on deposit surfaces led to lack of fusion pores. To mitigate sinter formation and its detrimental effects on DED component quality, it is essential that the powder delivery spot area is smaller than the melt pool, ensuring most powder lands in the melt pool.
| Type: | Article |
|---|---|
| Title: | Sinter formation during directed energy deposition of titanium alloy powders |
| Open access status: | An open access version is available from UCL Discovery |
| DOI: | 10.1016/j.ijmachtools.2022.103887 |
| Publisher version: | https://doi.org/10.1016/j.ijmachtools.2022.103887 |
| Language: | English |
| Additional information: | © 2022 The Authors. Published by Elsevier Ltd. under a Creative Commons license (https://creativecommons.org/licenses/by/4.0/). |
| Keywords: | Laser additive manufacturing, Directed energy deposition, Synchrotron X-ray imaging, Sintering, Porosity formation |
| UCL classification: | UCL > Provost and Vice Provost Offices > UCL BEAMS > Faculty of Engineering Science UCL > Provost and Vice Provost Offices > UCL BEAMS > Faculty of Engineering Science > Dept of Mechanical Engineering UCL > Provost and Vice Provost Offices > UCL BEAMS UCL |
| URI: | https://discovery.ucl.ac.uk/id/eprint/10149100 |
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