Machine learning-enabled real-time anomaly detection for electron beam powder bed fusion additive manufacturing

PurposeThis paper aims to present a systematic approach in the literature survey related to metal additive manufacturing (AM) processes and its multi-physics continuum modelling approach for its better understanding.Design/methodology/approachA systematic review of the literature available in the area of continuum modelling practices adopted for the powder bed fusion (PBF) AM processes for the deposition of powder layer over the substrate along with quantification of residual stress and distortion. Discrete element method (DEM) and finite element method (FEM) approaches have been reviewed for the deposition of powder layer and thermo-mechanical modelling, respectively. Further, thermo-mechanical modelling adopted for the PBF AM process have been discussed in detail with its constituents. Finally, on the basis of prediction through thermo-mechanical models and experimental validation, distortion mitigation/minimisation techniques applied in PBF AM processes have been reviewed to provide a future direction in the field.FindingsThe findings of this paper are the future directions for the implementation and modification of the continuum modelling approaches applied to PBF AM processes. On the basis of the extensive review in the domain, gaps are recommended for future work for the betterment of modelling approach.Research limitations/implicationsThis paper is limited to review only the modelling approach adopted by the PBF AM processes, i.e. modelling techniques (DEM approach) used for the deposition of powder layer and macro-models at process scale for the prediction of residual stress and distortion in the component. Modelling of microstructure and grain growth has not been included in this paper.Originality/valueThis paper presents an extensive review of the FEM approach adopted for the prediction of residual stress and distortion in the PBF AM processes which sets the platform for the development of distortion mitigation techniques. An extensive review of distortion mitigation techniques has been presented in the last section of the paper, which has not been reviewed yet.

Designers have been fascinated by exploring new geometries made by high-performance structures. In more specific terms, biological systems have always been proven to be characterised by sophisticated structures with adapting properties to nature challenges. Insightful analyses have shown how these natural structures are dominated by characteristics such as high energy absorption and elevated strength-weight proportion. Fractal geometries are examples of bio-inspired mathematical objects whose complex 3D structures can be obtained only by advanced manufacturing systems, such as additive manufacturing (AM). This study investigates the feasibility and energy absorption properties of a novel fractal structure based on a 3D Greek cross (3D-CFS). The structure was designed with different volume fractions and produced by powder bed fusion (PBF) AM processes in polyamide (PA12) and thermoplastic polyurethane (TPU). The 3D-CFS properties are investigated under quasi-static and dynamic compression tests. The analysis revealed that for certain geometrical parameters, the manufacturing of the structures is constrained by the sintered powder entrapped in the structure. However, in the case of powder-free structures, the results showed a high impact resistance and cushioning capability. Overall, in terms of specific energy absorption (SEA), the TPU structures showed values between 2.5 and 3.5 kJ/kg, while PA12 ones are between 7.5 and 17.4 kJ/kg, making the 3D-CFS structure compatible with personal protective equipment (PPE) applications. Compared to the literature data on cellular structures made by AM, 3D-CFS performs considerably better. Also, PA12 3D-CFS is better, with a SEA value up to 170% higher than that of a typical material employed for head PPE (e.g. EPS-60 SEA equal to 2.76 kJ/kg). In contrast, TPU 3D-CFS looks more promising in the case of multiple impact conditions.

Hybrid microstructure-defect printability map in laser powder bed fusion additive manufacturing

At the Johns Hopkins University Applied Physics Laboratory (APL), glass bead-filled polyamide (a.k.a. nylon) (GFN) is being used frequently for functional parts and systems, built using a laser-based powder bed fusion (PBF) additive manufacturing (AM) system. Since these parts have performance requirements, it is important to understand the mechanical properties of the additively-made GFN as a function of build orientation and build parameters. In addition, the performance of the AM system used to manufacture these parts must be evaluated in order to understand its capabilities, especially in order to determine the dimensional precision and repeatability of features built with this system. This paper summarizes recent APL efforts to characterize the GFN powder, the mechanical properties of parts made with GFN, and the performance of the laser PBF machine while running GFN using an AM test artifact.

Temperature gradient induced tough-brittle transition behavior of a high-strength Al-4.2Mg-0.4Sc-0.2Zr alloy fabricated by laser powder bed fusion additive manufacturing

This research aims at evaluating the characteristics of the 5 wt.% B4C/Ti-6Al-4V composite powder feedstock prepared by two different categories of mechanical mixing for powder bed fusion (PBF) additive manufacturing (AM) of metal matrix composites (MMCs). Microstructural features, particle size, size distribution, sphericity, conditioned bulk density and flow behavior of the developed powders were examined. The flowability of the regularly mixed powders was significantly lower than that of the Ti-6Al-4V powder. However, the flowability of the ball-milled systems was a significant function of the milling time. The decrease in the flowability of the 2 h ball-milled powder compared to the Ti-6Al-4V powder was attributed to the mechanical interlocking and the entangling caused by the B4C particles fully decorating the Ti-6Al-4V particles. Although the flattened/irregular shape of powder particles in the 6 h milled system acted to reduce the flowability, the overall surface area reduction led to higher flowability than that for the 2 h milling case. Regardless of the mixing method, incorporation of B4C particles into the system decreased the apparent density of the Ti-6Al-4V powder. The composite powder obtained by 2 h of ball milling was suggested as the best possible condition, meeting the requirements of PBF–AM processes.

An in-depth characterization of microstructure and mechanical properties of CuCrZr alloy processed by electron beam powder bed fusion (EB-PBF) additive manufacturing technology was performed with the aim to investigate the effect the thermal history of the material during the building process has on the properties of printed parts. Fully dense samples with a relative density up to 99.77 ± 0.04 % were successfully obtained in optimized conditions. The samples in the as-built condition exhibit an anisotropic microstructure dependent on the energetic input. An extensive microstructural transformation occurs alongside the precipitation and segregation of chromium-rich species, driven by the elevated thermal conditions during the deposition process. This unique thermal evolution can be properly investigated and exploited to eliminate the need for further post-processing heat treatments. To identify and quantify the precipitations within the microstructure, scanning and transmission electron microscopy together with electron backscattered diffraction were used.

This research program investigated the effects of layer thickness (50 µm and 100 µm) on the microstructure and mechanical properties of electron beam powder bed fusion (EBPBF) additive manufacturing of Inconel 625 alloy. The as-built 50 µm and 100 µm layer thickness components were also heat treated at temperatures above 1100 °C which produced a recrystallized grain structure containing annealing twins in the 50 µm layer thickness components, and a duplex grain structure consisting of islands of very small equiaxed grains dispersed in a recrystallized, large-grain structure containing annealing twins. The heat-treated components of the microstructures and mechanical properties were compared with the as-built components in both the build direction (vertical) and perpendicular (horizontal) to the build direction. Vickers microindentation hardness (HV) values for the vertical and horizontal geometries averaged 227 and 220 for the as-built 50 µm and 100 µm layer components, respectively, and 185 and 282 for the corresponding heat-treated components. The yield stress values were 387 MPa and 365 MPa for the as-built horizontal and vertical 50 µm layer geometries, and 330 MPa and 340 MPa for the as-built 100 µm layer components. For the heat-treated 50 µm components, the yield stress values were 340 and 321 MPa for the horizontal and vertical geometries, and 581 and 489 MPa for the 100 µm layer components, respectively. The elongation for the 100 µm layer as-built horizontal components was 28% in contrast with 65% for the corresponding 100 µm heat-treated layer components, an increase of 132% for the duplex grain structure.

Despite the widespread use of the electron beam powder bed fusion (EB-PBF) additive manufacturing (AM) process in the fabrication of cellular structures, relatively little is known about the microstructural and mechanical properties of the individual cellular struts of different geometries fabricated by the EB-PBF. In this study, experimental investigation was carried out in the attempt to establish preliminary understanding of the material characteristics of the Ti6Al4V cellular struts using EB-PBF under various geometry design conditions (dimension and orientation angle). It was found that there exist significant geometry effects for the material characteristics of the Ti6Al4V cellular struts, which indicates that a non-uniform material model should be considered in the future design of these cellular structures.

Printability and properties of tungsten cemented carbide produced using laser powder bed fusion additive manufacturing with Ti as a binder

A solidification mode selection process map for laser powder bed fusion additive manufacturing of B-modified Ti6Al4V

Coarse – and fine-grained bimodal-structures in a Al-Mg base alloy with rare earth elements of Sc/Zr is produced due to the ultrafast nonequilibrium solidification occurs in laser-induced molten pools during laser powder bed fusion (LPBF) additive manufacturing. A novel high-fidelity cellular automaton (CA) algorithm incorporating numerical calculations of molt-pool temperature fields elucidates the formation and evolution of the bimodal-structure. Subsequent heat treatment induces precipitation of Al3(Sc/Zr) particles within the grains, synergistically enhancing strength and plasticity of the LPBF-processed alloy. The crystal plastic finite element method (CPFEM) is used to reveal the synergistic effect between the strength and plasticity during the material tensile procedure. The bimodal-structure exhibits good fatigue resistance but intriguing anisotropy under low stress cyclic loading. It is proved that differentiated distribution patterns relative to the principal stress direction of the bimodal-structure have a significant influence on its fatigue performance. Numerical evolutionary of the bimodal grain deformation reflects this phenomenon.

Transient dynamics of powder spattering in laser powder bed fusion additive manufacturing process revealed by in-situ high-speed high-energy x-ray imaging

In-process failure analysis of thin-wall structures made by laser powder bed fusion additive manufacturing

The surface quality of inclined parts made by Laser powder-bed fusion (L-PBF) additive manufacturing is inferior to those made by conventional formative and subtractive manufacturing techniques. The inherited step edges formed during such layer-by-layer fabrications and partially melted or non-melted particles attached to the newly formed surface are the major causes of poor surface finish of L-PBF parts. This study is a part of a research framework, in which the effects of different contouring strategies and scan parameters on the surface morphology of inclined parts are investigated by both experimental and numerical methods. In particular, the effect of two different contour scan strategies, namely pre-contouring and post-contouring, on the upskin surface roughness of 30⁰ inclined parts is analyzed. The inclined specimens were fabricated with Ti6Al4V powder using an EOS M270 system and the upskin surfaces were measured by a white light interferometer. In addition, a multi-track multi-layer numerical approach using coupled discrete element method and thermo-fluid simulation was also performed to understand the inclined surface formation in L-PBF.The findings show that the pre-contouring strategy with high linear energy density (LED) (0.4 J/mm) results in average surface roughness (Sa) as low as 7.43 µm, whereas the lowest LED (0.05 J/mm) resulted in the highest Sa of 33.74 µm. Larger melt pool dimensions were obtained in the high LED pre-contouring simulations, which indicates a better material fusion resulting in a good surface finish. The numerical simulation showed that the upskin surface roughness is also affected by the raster scan, if the raster scanning LED is higher than that of pre-contour scans. For the post-contouring strategy studied, higher and lower LEDs were used in inner and outer contour scanning, respectively. It is indicated that the inner contour scanning with a high LED reduces the surface roughness because of a larger melt pool size, irrespective of outer contour scanning. The lowest Sa obtained was 8.24 µm for the highest LED inner contour (0.05 J/mm) case and the highest Sa was 19.95 µm, for the parts made with the lowest LED inner contour scan (0.075 J/mm) strategy. The coupled discrete-element and thermo-fluid-based simulations offer insights into the sloped surface formation and the results supported the experimental findings in qualitative manner.