Chinese Journal of Mechanical Engineering >

2023 , Vol. 36 >Issue 2: 32 - 32

DOI: https://doi.org/10.1186/s10033-023-00863-z

2023-4-25

Investigation of the Laser Powder Bed Fusion Process of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si Alloy

  • Changchun Zhang ,
  • Tingting Liu ,
  • Wenhe Liao ,
  • Huiliang Wei ,
  • Ling Zhang
Expand
  • 1. School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing 210094, China;
    2. School of Mechanical and Vehicle Engineering, West Anhui University, Luan 237012, China

Received date: 2021-11-02

  Revised date: 2022-10-21

  Online published: 2023-12-21

Supported by

Supported by Development of a Verification Platform for Product Design, Process, and Information Exchange Standards in Additive Manufacturing (Grant No. 2019-00899-1-1), Ministry of Science and Technology of the People's Republic of China (Grant No. 2017YFB1103000), National Natural Science Foundation of China (Grant No. 51375242), and Natural Science Foundation of Jiangsu Province (Grant No. BK20180483)

Fold

Abstract

Laser powder bed fusion (LPBF) is an advanced manufacturing technology; however, inappropriate LPBF process parameters may cause printing defects in materials. In the present work, the LPBF process of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy was investigated by a two-step optimization approach. Subsequently, heat transfer and liquid flow behaviors during LPBF were simulated by a well-tested phenomenological model, and the defect formation mechanisms in the as-fabricated alloy were discussed. The optimized process parameters for LPBF were detected as laser power changed from 195 W to 210 W, with scanning speed of 1250 mm/s. The LPBF process was divided into a laser irradiation stage, a spreading flow stage, and a solidification stage. The morphologies and defects of deposited tracks were affected by liquid flow behavior caused by rapid cooling rates. The findings of this research can provide valuable support for printing defect-free metal components.

Key words： Laser powder bed fusion; Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy; Process parameters; Heat transfer and liquid flow; Defects

Cite this article

Changchun Zhang , Tingting Liu , Wenhe Liao , Huiliang Wei , Ling Zhang . Investigation of the Laser Powder Bed Fusion Process of Ti-6.5Al-3.5Mo-1.5Zr-0.3Si Alloy[J]. Chinese Journal of Mechanical Engineering, 2023 , 36(2) : 32 -32 . DOI: 10.1186/s10033-023-00863-z

References

[1] T DebRoy, H L Wei, J S Zuback, et al. Additive manufacturing of metallic components - Process, structure and properties. Progress in Materials Science, 2018, 92: 112-224.
[2] E Stepanova, N Pushilina, M Syrtanov, et al. Hydrogen effect on Ti-6.5Al-3.5Mo-1.5Zr-0.3Si parts produced by electron beam melting. International Journal of Hydrogen Energy, 2019, 44(55): 29380-29388.
[3] Y Chen, C Yang, C Fan, et al. Grain refinement of additive manufactured Ti-6.5Al-3.5Mo-1.5Zr-0.3Si titanium alloy by the addition of La2O3. Materials Letters, 2020, 275: 128170.
[4] W T Yan, W J Ge, Y Qian, et al. Multi-physics modeling of single/multiple-track defect mechanisms in electron beam selective melting. Acta Materialia, 2017, 134: 324-333.
[5] A Aversa, M Moshiri, E Librera, et al. Single scan track analyses on aluminium based powders. Journal of Materials Processing Technology, 2018, 255: 17-25.
[6] P Promoppatum, R Srinivasan, S S Quek, et al. Quantification and prediction of lack-of-fusion porosity in the high porosity regime during laser powder bed fusion of Ti-6Al-4V. Journal of Materials Processing Technology, 2022, 300: 117426.
[7] R Molaei, A Fatemi, N Sanaei, et al. Fatigue of additive manufactured Ti-6Al-4V, Part II: The relationship between microstructure, material cyclic properties, and component performance. International Journal of Fatigue, 2020, 132: 105363.
[8] Y Liu, C Liu, W S Liu, et al. Optimization of parameters in laser powder deposition AlSi10Mg alloy using Taguchi method. Optics and Laser Technology, 2019, 111: 470-480.
[9] S Sanchez, C J Hyde, I A Ashcroft, et al. Multi-laser scan strategies for enhancing creep performance in LPBF. Additive Manufacturing, 2021, 41: 101948.
[10] H Gong, K Rafi, H Gu, et al. Analysis of defect generation in Ti-6Al-4V parts made using powder bed fusion additive manufacturing processes. Additive Manufacturing, 2014, 1-4: 87-98.
[11] Z Wang, Z Y Xiao, Y Tse, et al. Optimization of processing parameters and establishment of a relationship between microstructure and mechanical properties of SLM titanium alloy. Optics and Laser Technology, 2019, 112: 159-167.
[12] T Yang, T T Liu, W H Liao, et al. The influence of process parameters on vertical surface roughness of the AlSi10Mg parts fabricated by selective laser melting. Journal of Materials Processing Technology, 2019, 266: 26-36.
[13] I Yadroitsev, P Krakhmalev, I Yadroitsava. Selective laser melting of Ti6Al4V alloy for biomedical applications: Temperature monitoring and microstructural evolution. Journal of Alloys and Compounds, 2014, 583: 404-409.
[14] S Y Yamamoto, H S Azuma, S Suzuki, et al. Melting and solidification behavior of Ti-6Al-4V powder during selective laser melting. The International Journal of Advanced Manufacturing Technology, 2019, 103(9-12): 4433-4442.
[15] T Furumoto, K Egashira, K Munekage, et al. Experimental investigation of melt pool behaviour during selective laser melting by high speed imaging. Cirp Annals-Manufacturing Technology, 2018, 67(1): 253-256.
[16] M J Matthews, G Guss, S A Khairallah, et al. Denudation of metal powder layers in laser powder bed fusion processes. Acta Materialia, 2016, 114: 33-42.
[17] P Bidare, I Bitharas, R M Ward, et al. Laser powder bed fusion at sub-atmospheric pressures. International Journal of Machine Tools and Manufacture, 2018, 130: 65-72.
[18] S Y Pang, W D Chen, J X Zhou, et al. Self-consistent modeling of keyhole and weld pool dynamics in tandem dual beam laser welding of aluminum alloy. Journal of Materials Processing Technology, 2015, 217: 131-143.
[19] H L Wei, Y Cao, W H Liao, et al. Mechanisms on inter-track void formation and phase transformation during laser powder bed fusion of Ti-6Al-4V. Additive Manufacturing, 2020, 34: 101221.
[20] S A Khairallah, A T Anderson, A Rubenchik, et al. Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones. Acta Materialia, 2016, 108: 36-45.
[21] T Zhang, H Li, S Liu, et al. Evolution of molten pool during selective laser melting of Ti-6Al-4V. Journal of Physics D-Applied Physics, 2019, 52(5): 055302.
[22] C Tang, J L Tan, C H Wong. A numerical investigation on the physical mechanisms of single track defects in selective laser melting. International Journal of Heat and Mass Transfer, 2018, 126: 957-968.
[23] Z Wang, W Yan, W K Liu, et al. Powder-scale multi-physics modeling of multi-layer multi-track selective laser melting with sharp interface capturing method. Computational Mechanics, 2018, 63(4): 649-661.
[24] L Zhang, W H Liao, T T Liu, et al. In situ elimination of pores during laser powder bed fusion of Ti-6.5Al-3.5Mo-l. 5Zr-0.3Si titanium alloy. Acta Metallurgica Sinica (English Letters), 2021, 35(3): 439-452.
[25] X Zhou, X H Liu, D D Zhang, et al. Balling phenomena in selective laser melted tungsten. Journal of Materials Processing Technology, 2015, 222: 33-42.
[26] W H Yu, S L Sing, C K Chua, et al. Particle-reinforced metal matrix nanocomposites fabricated by selective laser melting: A state of the art review. Progress in Materials Science, 2019, 104: 330-379.
[27] J Yin, D Wang, H Wei, et al. Dual-beam laser-matter interaction at overlap region during multi-laser powder bed fusion manufacturing. Additive Manufacturing, 2021, 46: 02178.
[28] B Song, S Dong, H Liao, et al. Process parameter selection for selective laser melting of Ti6Al4V based on temperature distribution simulation and experimental sintering. The International Journal of Advanced Manufacturing Technology, 2011, 61(9-12): 967-974.
[29] B U Scipioni, G Guss, S Wu, et al. In-situ characterization of laser-powder interaction and cooling rates through high-speed imaging of powder bed fusion additive manufacturing. Materials & Design, 2017, 135: 385-396.
[30] J J Yang, J Han, H C Yu, et al. Role of molten pool mode on formability, microstructure and mechanical properties of selective laser melted Ti-6Al-4V alloy. Materials & Design, 2016, 110: 558-570.
[31] P Bidare, I Bitharas, R M Ward, et al. Fluid and particle dynamics in laser powder bed fusion. Acta Materialia, 2018, 142: 107-120.
[32] A F H Kaplan. Local absorptivity modulation of a 1μm-laser beam through surface waviness. Applied Surface Science, 2012, 258(24): 9732-9736.
[33] M Ghayoor, K Lee, Y He, et al. Selective laser melting of 304L stainless steel: Role of volumetric energy density on the microstructure, texture and mechanical properties. Additive Manufacturing, 2020, 32: 101011.
[34] A V Gusarov, I Yadroitsev, P Bertrand, et al. Heat transfer modelling and stability analysis of selective laser melting. Applied Surface Science, 2007, 254(4): 975-979.
[35] S Y Liu, Y C Shin. Additive manufacturing of Ti6Al4V alloy: A review. Materials & Design, 2019, 164: 107552.
[36] C C Zhang, H L Wei, T T Liu, et al. Influences of residual stress and micro-deformation on microstructures and mechanical properties for Ti-6.5Al-3.5Mo-1.5Zr-0.3Si alloy produced by laser powder bed fusion. Journal of Materials Science & Technology, 2021, 75: 174-183.
Options
Outlines

/

〈 〉

　 Copyright © Chinese Journal of Mechanical Engineering, All Rights Reserved.
Powered by Beijing Magtech Co. Ltd,.