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Study of Powder Gas Entrapment and Its Effects on Porosity in 17-4 PH Stainless Steel Parts Fabricated in Laser Powder Bed Fusion

  • In Situ Synchrotron and Neutron Characterization of Additively Manufactured Alloys
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Abstract

Powder-entrapped gas, which can occur naturally in gas-atomized powder, can induce porosity in parts fabricated with powder-based metal additive manufacturing processes. This study utilized synchrotron-based x-ray computed tomography and an in situ high-speed imaging technique, dynamic x-ray radiography (DXR), to investigate the formation of powder-induced porosity using 17-4 PH stainless steel powders with a controlled size distribution and intentionally varied entrapped gas contents. While powder with a low entrapped gas content showed no net part porosity increase, the results showed a strong correlation between the porosity in the powder and the porosity in the builds made from powder with a high entrapped gas content relative to typical gas-atomized powder. A threshold value was developed to classify porosity induced by powder-entrapped gas based on pore morphology measured using computed tomography. Transfer and coalescence of pores during laser melting was observed directly with DXR.

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Acknowledgements

The authors acknowledge the support of the NextManufacturing Center at Carnegie Mellon University. Specifically, Todd Baer is acknowledged for sample fabrication and preparation, Danli Luo for helping with the preparation of figures, and Dr. Sandra DeVincent Wolf for helpful discussions. The authors also recognize Carpenter Technology Corporation, especially the support of James Scanlon, for contributions to this research. This research 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. Dr. Xianghui Xiao, Dr. Pavel Shevchenko, and all the 2-BM beamline staff at the Advanced Photon Source are thanked for assisting in the acquisition of the synchrotron tomography data. Dr. Tao Sun, Dr. Niranjan Parab, Dr. Cang Zhao and all the 32-ID beamline staff at the Advanced Photon Source are thanked for assisting in the acquisition of the DXR data.

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Author notes

  1. John L. L. Meyer

    Present address: 6K, Inc., 25 Commerce Way, North Andover, MA, USA

  2. Elizabeth Larson

    Present address: Ultra Fine Specialty Products, 500 Park East Drive, Woonsocket, RI, USA

  3. Ziheng Wu and Debomita Basu have contributed equally.

Authors and Affiliations

  1. Department of Materials Science and Engineering, Carnegie Mellon University, 5000 Forbes Ave, Pittsburgh, PA, 15213, USA

    Ziheng Wu, Debomita Basu, Robin Kuo & Anthony Rollett

  2. Carpenter Technology Corporation, 101 West Bern Street, Reading, PA, 19601, USA

    John L. L. Meyer

  3. Carpenter Powder Products, 500 Park East Drive, Woonsocket, RI, USA

    Elizabeth Larson

  4. Department of Mechanical Engineering, Carnegie Mellon University, 5000 Forbes Ave, Pittsburgh, PA, 15213, USA

    Jack Beuth

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Wu, Z., Basu, D., Meyer, J.L.L. et al. Study of Powder Gas Entrapment and Its Effects on Porosity in 17-4 PH Stainless Steel Parts Fabricated in Laser Powder Bed Fusion. JOM 73, 177–188 (2021). https://doi.org/10.1007/s11837-020-04491-z

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  • DOI: https://doi.org/10.1007/s11837-020-04491-z

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