Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction

Abstract We employ the high-speed synchrotron hard X-ray imaging and diffraction techniques to monitor the laser powder bed fusion (LPBF) process of Ti-6Al-4V in situ and in real time. We demonstrate that many scientifically and technologically significant phenomena in LPBF, including melt pool dynamics, powder ejection, rapid solidification, and phase transformation, can be probed with unprecedented spatial and temporal resolutions. In particular, the keyhole pore formation is experimentally revealed with high spatial and temporal resolutions. The solidification rate is quantitatively measured, and the slowly decrease in solidification rate during the relatively steady state could be a manifestation of the…

• UD
  U.S. Department of Energy

  Awards: AC02-06CH11357, Contract No. DE-AC02-06CH11357, DE-AC02, 06CH11357, No. DE-AC02-06CH11357, DE-AC02-06CH11357, DE-AC02-
• NG
  Northrop Grumman
• PU
  Purdue University
• UO
  University of Missouri
• OO
  Office of Science

  Awards: DE-AC02-06CH11357, Contract No. DE-AC02-06CH11357, DE-AC02, No. DE-AC02-06CH11357, 06CH11357, AC02-06CH11357
• LD
  Laboratory Directed Research and Development

  Awards: No. DE-AC02-06CH11357, DE-AC02-06CH11357
• AN
  Argonne National Laboratory

  Awards: DE-AC02, No. DE-AC02-06CH11357, 06CH11357, AC02-06CH11357, Contract No. DE-AC02-06CH11357
• AF
  Air Force Research Laboratory