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Cross-Sectional Melt Pool Geometry of Laser Scanned Tracks and Pads on Nickel Alloy 718 for the 2022 Additive Manufacturing Benchmark Challenges

Published

Author(s)

Jordan Weaver, David Deisenroth, Sergey Mekhontsev, Brandon Lane, Lyle E. Levine, Ho Yeung

Abstract

AM Bench is a NIST-led organization that provides a continuing series of additive manufacturing (AM) benchmark measurements, challenge problems, and conferences with the primary goal of enabling modelers to test their simulations against rigorous, highly controlled additive manufacturing benchmark measurement data. To this end, single track (1D) and pad (2D) scans on bare plate nickel alloy 718 were completed with thermography, cross-sectional grain orientation and local chemical composition maps, and cross-sectional melt pool size measurements. The laser power, scan speed, and laser spot size were varied for single tracks, and the scan direction was varied for pads. This article focuses on the cross-sectional melt pool size measurements and presents the predictions from challenge problems. Single track depth correlated with volumetric energy density while width did not (within the studied parameters). The melt pool size for pad scans was greater than single tracks due to heat buildup. Pad scan melt pool depth was reduced when the laser scan direction and gas flow direction were parallel. The melt pool size in pad scans showed little to no trend against position within the pads. Uncertainty budgets for cross-sectional melt pool size from optical micrographs are provided for the purpose of model validation.
Citation
Integrating Materials and Manufacturing Innovation

Keywords

laser powder bed fusion, melt pool size, optical microscopy, model validation

Citation

Weaver, J. , Deisenroth, D. , Mekhontsev, S. , Lane, B. , Levine, L. and Yeung, H. (2024), Cross-Sectional Melt Pool Geometry of Laser Scanned Tracks and Pads on Nickel Alloy 718 for the 2022 Additive Manufacturing Benchmark Challenges, Integrating Materials and Manufacturing Innovation, [online], https://doi.org/10.1007/s40192-024-00355-5, https://tsapps.nist.gov/publication/get_pdf.cfm?pub_id=957295 (Accessed June 17, 2024)

Issues

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Created May 7, 2024, Updated June 7, 2024