Spot pattern welding scanning strategy for sensor embedding and residual stress reduction in laser-foil-printing additive manufacturing

• Published in: Rapid prototyping journal 2025-01, Vol.31 (1), p.83-99
• Main Authors: Turk, Tunay, Dominguez, Cesar E., Sutton, Austin T., Bernardin, John D., Park, Jonghyun, Leu, Ming C.
• Format: Article
• Language: English
• Subjects: Additive manufacturing; Aluminum; Automation; Beads; Cooling; Embedded sensors; Embedding; Grain size; High temperature; Imaging techniques; Laser beam welding; Lasers; Manufacturing; Marangoni convection; Melt pools; Metal foils; Raster scanning; Raw materials; Research methodology; Residual stress; Sensors; Spot welds; Steel alloys; Strategy; Temperature gradients
• ISSN: 1355-2546; 1758-7670
• DOI: 10.1108/RPJ-01-2024-0042

Purpose This paper aims to present spot pattern welding (SPW) as a scanning strategy for laser-foil-printing (LFP) additive manufacturing (AM) in place of the previously used continuous pattern welding (CPW) (line-raster scanning). The SPW strategy involves generating a sequence of overlapping spot welds on the metal foil, allowing the laser to form dense and uniform weld beads. This in turn reduces thermal gradients, promotes material consolidation and helps mitigate process-related risks such as thermal cracking, porosity, keyholing and Marangoni effects. Design/methodology/approach 304L stainless steel (SS) feedstock is used to fabricate test specimens using the LFP system. Imaging techniques are used to examine the melt pool dimensions and layer bonding. In addition, the parts are evaluated for residual stresses, mechanical strength and grain size. Findings Compared to CPW, SPW provides a more reliable heating/cooling relationship that is less dependent on part geometry. The overlapping spot welds distribute heat more evenly, minimizing the risk of elevated temperatures during the AM process. In addition, the resulting dense and uniform weld beads contribute to lower residual stresses in the printed part. Originality/value To the best of the authors’ knowledge, this is the first study to thoroughly investigate SPW as a scanning strategy using the LFP process. In general, SPW presents a promising strategy for securing embedded sensors into LFP parts while minimizing residual stresses.