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Modeling and Monitoring of the Effect of Scan Strategy on Microstructure in Additive Manufacturing

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Abstract

Laser powder bed fusion is an additive manufacturing process that uses a selective melting technique to build three-dimensional metal structures. This fabrication technique is useful for creating complex parts with fine resolution. However, the repeated scanning method used throughout the process results in complex thermal behavior, which introduces microstructural variations and defects in the final part. The semi-analytical model used in this work calculates the temperature distributions and thermal conditions in laser powder bed fusion to predict the microstructural variations. Additionally, an in situ process monitoring approach is used to verify the predicted influence of the processing parameters and scan strategy on the microstructure of the printed parts.

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Acknowledgements

This work was funded by an Ohio Space Grant Consortium Fellowship, and a NASA STTR Phase II-X. The authors would like to thank Dr. Alex Plotkowski from Oak Ridge National Laboratory for valuable conversations and the development of the semi-analytical modeling code used in this work.

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Authors and Affiliations

  1. Department of Mechanical and Materials Engineering, Wright State University, Dayton, OH, 45435, USA

    Rachel Evans, Joseph Walker & Joy Gockel

  2. Universal Technology Company, Dayton, OH, 45432, USA

    Joseph Walker & John Middendorf

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  1. Rachel Evans
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  2. Joseph Walker
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  4. Joy Gockel
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Correspondence to Joy Gockel.

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Manuscript submitted September 18, 2019.

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Evans, R., Walker, J., Middendorf, J. et al. Modeling and Monitoring of the Effect of Scan Strategy on Microstructure in Additive Manufacturing. Metall Mater Trans A 51, 4123–4129 (2020). https://doi.org/10.1007/s11661-020-05830-0

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