Details
| Original language | English |
|---|---|
| Pages (from-to) | 199-210 |
| Number of pages | 12 |
| Journal | Acta materialia |
| Volume | 176 |
| Early online date | 5 Jul 2019 |
| Publication status | Published - 1 Sept 2019 |
Abstract
We propose a methodology for predicting the printability of an alloy, subject to laser powder bed fusion additive manufacturing. Regions in the process space associated with keyhole formation, balling, and lack of fusion are assumed to be strong functions of the geometry of the melt pool, which in turn is calculated for various combinations of laser power and scan speed via a Finite Element thermal model that incorporates a novel vaporization-based transition from surface to volumetric heating upon keyhole formation. Process maps established from the Finite Element simulations agree with experiments for a Ni-5wt.%Nb alloy and an equiatomic CoCrFeMnNi High Entropy Alloy and suggest a strong effect of chemistry on alloy printability. The printability maps resulting from the use of the simpler Eagar-Tsai model, on the other hand, are found to be in disagreement with experiments due to the oversimplification of this approach. Uncertainties in the printability maps were quantified via Monte Carlo sampling of a multivariate Gaussian Processes surrogate model trained on simulation outputs. The printability maps generated with the proposed method can be used in the selection—and potentially the design—of alloys best suited for Additive Manufacturing.
Keywords
- Additive manufacturing, High entropy alloys, NiNb, Printability, Selective laser melting
ASJC Scopus subject areas
- Materials Science(all)
- Electronic, Optical and Magnetic Materials
- Materials Science(all)
- Ceramics and Composites
- Materials Science(all)
- Polymers and Plastics
- Materials Science(all)
- Metals and Alloys
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In: Acta materialia, Vol. 176, 01.09.2019, p. 199-210.
Research output: Contribution to journal › Article › Research › peer review
}
TY - JOUR
T1 - Assessing printability maps in additive manufacturing of metal alloys
AU - Johnson, Luke
AU - Mahmoudi, Mohamad
AU - Zhang, Bing
AU - Seede, Raiyan
AU - Huang, Xueqin
AU - Maier, Janine T.
AU - Maier, Hans Jürgen
AU - Karaman, Ibrahim
AU - Elwany, Alaa
AU - Arróyave, Raymundo
N1 - Funding information: The authors would like to acknowledge the support of the Army Research Office under Contract No. W911NF-18-1-0278 . Portions of this work were also (partially supported by NASA through Grant No. NNX15AD71G. LJ would also like to acknowledge the NSF-NRT fellowship support through the National Science Foundation grant No. NSF-DGE-1545403 , NRT-DESE: Data-Enabled Discovery and Design of Energy Materials (DEM) . Finite Element Model simulations were carried out in the Texas A&M Supercomputing Facility.
PY - 2019/9/1
Y1 - 2019/9/1
N2 - We propose a methodology for predicting the printability of an alloy, subject to laser powder bed fusion additive manufacturing. Regions in the process space associated with keyhole formation, balling, and lack of fusion are assumed to be strong functions of the geometry of the melt pool, which in turn is calculated for various combinations of laser power and scan speed via a Finite Element thermal model that incorporates a novel vaporization-based transition from surface to volumetric heating upon keyhole formation. Process maps established from the Finite Element simulations agree with experiments for a Ni-5wt.%Nb alloy and an equiatomic CoCrFeMnNi High Entropy Alloy and suggest a strong effect of chemistry on alloy printability. The printability maps resulting from the use of the simpler Eagar-Tsai model, on the other hand, are found to be in disagreement with experiments due to the oversimplification of this approach. Uncertainties in the printability maps were quantified via Monte Carlo sampling of a multivariate Gaussian Processes surrogate model trained on simulation outputs. The printability maps generated with the proposed method can be used in the selection—and potentially the design—of alloys best suited for Additive Manufacturing.
AB - We propose a methodology for predicting the printability of an alloy, subject to laser powder bed fusion additive manufacturing. Regions in the process space associated with keyhole formation, balling, and lack of fusion are assumed to be strong functions of the geometry of the melt pool, which in turn is calculated for various combinations of laser power and scan speed via a Finite Element thermal model that incorporates a novel vaporization-based transition from surface to volumetric heating upon keyhole formation. Process maps established from the Finite Element simulations agree with experiments for a Ni-5wt.%Nb alloy and an equiatomic CoCrFeMnNi High Entropy Alloy and suggest a strong effect of chemistry on alloy printability. The printability maps resulting from the use of the simpler Eagar-Tsai model, on the other hand, are found to be in disagreement with experiments due to the oversimplification of this approach. Uncertainties in the printability maps were quantified via Monte Carlo sampling of a multivariate Gaussian Processes surrogate model trained on simulation outputs. The printability maps generated with the proposed method can be used in the selection—and potentially the design—of alloys best suited for Additive Manufacturing.
KW - Additive manufacturing
KW - High entropy alloys
KW - NiNb
KW - Printability
KW - Selective laser melting
UR - http://www.scopus.com/inward/record.url?scp=85068870634&partnerID=8YFLogxK
U2 - 10.1016/j.actamat.2019.07.005
DO - 10.1016/j.actamat.2019.07.005
M3 - Article
AN - SCOPUS:85068870634
VL - 176
SP - 199
EP - 210
JO - Acta materialia
JF - Acta materialia
SN - 1359-6454
ER -