In situ X-ray quantification of melt pool behaviour during directed energy deposition additive manufacturing of stainless steel

•In situ and operando synchrotron X-ray imaging reveal the laser induced phenomena;•How powder feedrate, laser power and traverse speed impact on surface quality.•Surface roughness is a result of melt pool surface perturbations.•Process maps quantitatively correlate build quality to process paramete...

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Bibliographic Details
Published in:Materials letters 2021-03, Vol.286, p.129205, Article 129205
Main Authors: Chen, Yunhui, Clark, Samuel J., Huang, Yuze, Sinclair, Lorna, Lun Alex Leung, Chu, Marussi, Sebastian, Connolley, Thomas, Magdysyuk, Oxana V., Atwood, Robert C., Baxter, Gavin J., Jones, Martyn A., Todd, Iain, Lee, Peter D.
Format: Article
Language:English
Subjects:
Additive manufacturing
Construction
Deposition
Directed energy deposition
Feed rate
In situ synchrotron X-ray imaging
Laser additive manufacturing
Materials science
Morphology
Perturbation
Process mapping
Process parameters
Stainless steels
Surface properties
Surface roughness
Synchrotron radiation
Synchrotrons
X ray imagery
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Summary:•In situ and operando synchrotron X-ray imaging reveal the laser induced phenomena;•How powder feedrate, laser power and traverse speed impact on surface quality.•Surface roughness is a result of melt pool surface perturbations.•Process maps quantitatively correlate build quality to process parameters.•The surface quality heavily relies on build parameter. The Directed Energy Deposition Additive Manufacturing (DED-AM) of SS316L was studied using in situ and operando synchrotron X-ray imaging to quantitively understand the effect of processing parameters on the melt-pool morphology and surface quality. It was found that surface roughness of DED-AM builds can result from melt pool surface perturbations caused by changes in the melt flow and build stage motion perturbations. Process maps are developed that quantitatively correlate build quality to process parameters including powder feed rate, laser power and traverse speed. How the AM process parameters control build efficacy is clarified, and the processing conditions required to dampen surface perturbations leading to roughness were determined.
ISSN:0167-577X
1873-4979
DOI:10.1016/j.matlet.2020.129205