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A review of high energy density beam processes for welding and additive manufacturing applications

  • Review Article
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Abstract

High-energy density beam processes for welding, including laser beam welding and electron beam welding, are essential processes in many industries and provide unique characteristics that are not available with other processes used for welding. More recently, these high-energy density beams have been used to great advantage for additive manufacturing. This review of the literature serves to provide an overview of the evolution of the laser and electron beam processes including the fundamental nature of the beam itself and how such a high-energy density beam has been applied for welding. The unique nature of each process regarding weld bead formation and penetration, and metallurgical considerations are covered in detail. In addition, the evolution of monitoring systems for both characterization and control of these beam processes is reviewed. Over 500 references have been cited in this comprehensive review that will allow the reader to both understand the current state-of-the-art and explore in more detail the fundamental concepts and practical applications of these processes.

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Abbreviations

AE:

acoustic emission

AM:

additive manufacturing

BPP:

beam parameter product

CAD:

computer-aided design

CCD:

charge-coupled device

CMOS:

complementary metal oxide semiconductors

CNC:

computer numerical control

CW:

continuous wave

DED:

direct energy deposition

DSS:

duplex stainless steel

EBW:

electron beam welding

EMFC:

enhanced modified Faraday cup

FWHM:

full width at half maximum (beam size measurement)

FZ:

fusion zone

HAZ:

heat-affected zone

HED:

high-energy density

HLAW:

hybrid laser-arc welding

ICI:

inline coherent imaging

LASER:

light amplification by stimulated emission of radiation

LBW:

laser beam welding

LED:

light-emitting diode

LENS™:

Laser-engineered net shaping

LPBF:

laser powder bed fusion

MASER:

microwave amplification by stimulated emission of radiation

NDE:

nondestructive evaluation

Nd:YAG:

neodymium doped yttrium aluminum garnet

OCT:

optical coherence tomography

PBF:

powder bed fusion

P-LBW:

pulsed laser beam welding

RPPM:

radiation pressure power meter

TEM:

transverse electromagnetic modes

YAG:

yttrium aluminum garnet

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Acknowledgements

This review was supported through the National Science Foundation (NSF) sponsored Industry/University Cooperative Research Center (I/UCRC): Manufacturing and Materials Joining Innovation Center (MA2JIC). The authors would like to thank Los Alamos National Laboratory (LANL) for providing financial support and, in particular, Dr. Matt Johnson and Dr. David Tung who have served as mentors for this project. Also, the authors would like to thank Dr. Pat Hochanadel and Dr. Tung from LANL, and Mr. Doug Kautz from Leidos Inc. for reviewing the manuscript and providing valuable input.

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    T. Patterson, J. Hochanadel, S. Sutton, B. Panton & J. Lippold

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Patterson, T., Hochanadel, J., Sutton, S. et al. A review of high energy density beam processes for welding and additive manufacturing applications. Weld World 65, 1235–1306 (2021). https://doi.org/10.1007/s40194-021-01116-0

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