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Probing Ultrafast Dynamics in Laser Powder Bed Fusion Using High-Speed X-Ray Imaging: A Review of Research at the Advanced Photon Source

  • The 2nd Asia-Pacific International Conference on Additive Manufacturing (APICAM 2019)
  • Published:
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Abstract

Additive manufacturing (AM) is a transformative technology that opens up many exciting opportunities. In metal AM processes, high-power heat sources are often used to locally fuse the metal feedstock to the previous layer. Extreme thermal conditions are involved and unique microstructures are developed in AM-processed materials. At the Advanced Photon Source, we applied high-speed x-ray imaging to probe the ultrafast dynamics of the vapor depression, melt flow and particle spattering, among other transient phenomena. Demonstrated by the scientific cases reviewed and cited here, high-speed x-ray imaging is a unique tool for metal AM research. It provides invaluable information that can help address the critical issues in AM associated with structural defects, high-fidelity models, build reliability and repeatability.

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Fig. 1
Fig. 2
Fig. 3

Reprinted with permission from Ref. [8] (Color figure online)

Fig. 4

Reprinted with permission from Ref. [10]

Fig. 5

Adapted from Ref. [12]

Fig. 6

The simulation is reprinted with permission from Ref. [13]

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Acknowledgements

This contribution summarizes the content I presented at the 2019 Asia–Pacific International Conference on Additive Manufacturing. The research described here was all performed and published at the time I worked at the Advanced Photon Source. I would like to thank all our team members and collaborators for their great efforts, particularly Prof. Anthony Rollett at Carnegie Mellon University, Prof. Lianyi Chen at University of Wisconsin-Madison, and Prof. Wenda Tan at University of Utah, who led some of the projects I introduced in this contribution. All research described here used resources of the Advanced Photon Source, a US Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under Contract No. DE-AC02-06CH11357.

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  1. Department of Materials Science and Engineering, University of Virginia, Charlottesville, VA, USA

    Tao Sun

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Sun, T. Probing Ultrafast Dynamics in Laser Powder Bed Fusion Using High-Speed X-Ray Imaging: A Review of Research at the Advanced Photon Source. JOM 72, 999–1008 (2020). https://doi.org/10.1007/s11837-020-04015-9

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