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Effects of Melt Pool Variables and Process Parameters in Laser Direct Metal Deposition of Aerospace Alloys

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Effects of Melt Pool Variables and Process Parameters in Laser Direct Metal Deposition of Aerospace Alloys. / Shah, Kamran; Pinkerton, Andrew J.; Salman, Ahmad et al.
In: Materials and Manufacturing Processes, Vol. 25, No. 12, 2010, p. 1372-1380.

Research output: Contribution to Journal/MagazineJournal articlepeer-review

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Shah K, Pinkerton AJ, Salman A, Li L. Effects of Melt Pool Variables and Process Parameters in Laser Direct Metal Deposition of Aerospace Alloys. Materials and Manufacturing Processes. 2010;25(12):1372-1380. doi: 10.1080/10426914.2010.480999

Author

Shah, Kamran ; Pinkerton, Andrew J. ; Salman, Ahmad et al. / Effects of Melt Pool Variables and Process Parameters in Laser Direct Metal Deposition of Aerospace Alloys. In: Materials and Manufacturing Processes. 2010 ; Vol. 25, No. 12. pp. 1372-1380.

Bibtex

@article{4047aedc0c204ef8b276a1ab1e0b529c,
title = "Effects of Melt Pool Variables and Process Parameters in Laser Direct Metal Deposition of Aerospace Alloys",
abstract = "Despite considerable advances in of laser direct metal deposition (LDMD) process optimization, there is rather limited work reported on the effects of melt pool variables on the final deposit characteristics. This article considers the effects of process parameters and melt pool characteristics on the deposition of Inconel 718 powder on a Ti-6Al-4V thin wall. A 1.5kW diode laser and LDMD system is used to produce a series of deposits. Images of the process are captured using Cu-vapor laser illumination and a high speed camera with long range microscopy optics, and quantitative results are extracted via image analysis. Process parameters such as carrier gas flow rate, powder mass flow rate and laser operating mode (CW and pulsed) and in process variables such as quantified melt pool disturbance, and final part characteristics are correlated and discussed. Scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and energy dispersive X-ray spectroscopy (EDS) are used to analyze deposited clads in terms of elemental composition and flow characteristics in the deposition melt pool. Melt pool disturbance is found to be a vital parameter in determining the surface roughness of the final part. An inverse relation between the mean surface disturbance of the melt pool and the surface roughness of the part is observed, and carrier gas flow rate and powder mass flow rate both affect the overall melt pool size. The work has implications for the selection of process parameters for commercial laser deposition processes-the speed with which powder is delivered to the melt pool as well as the mass flow rate may need to be taken into account when calculating build rate and for a good surface finish requiring minimum post process finishing a stable melt pool may actually be the worst situation.",
keywords = "Cladding, Deposition , Laser , Inconel , Ti-6Al-4 V",
author = "Kamran Shah and Pinkerton, {Andrew J.} and Ahmad Salman and Lin Li",
year = "2010",
doi = "10.1080/10426914.2010.480999",
language = "English",
volume = "25",
pages = "1372--1380",
journal = "Materials and Manufacturing Processes",
issn = "1042-6914",
publisher = "Taylor and Francis Ltd.",
number = "12",

}

RIS

TY - JOUR

T1 - Effects of Melt Pool Variables and Process Parameters in Laser Direct Metal Deposition of Aerospace Alloys

AU - Shah, Kamran

AU - Pinkerton, Andrew J.

AU - Salman, Ahmad

AU - Li, Lin

PY - 2010

Y1 - 2010

N2 - Despite considerable advances in of laser direct metal deposition (LDMD) process optimization, there is rather limited work reported on the effects of melt pool variables on the final deposit characteristics. This article considers the effects of process parameters and melt pool characteristics on the deposition of Inconel 718 powder on a Ti-6Al-4V thin wall. A 1.5kW diode laser and LDMD system is used to produce a series of deposits. Images of the process are captured using Cu-vapor laser illumination and a high speed camera with long range microscopy optics, and quantitative results are extracted via image analysis. Process parameters such as carrier gas flow rate, powder mass flow rate and laser operating mode (CW and pulsed) and in process variables such as quantified melt pool disturbance, and final part characteristics are correlated and discussed. Scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and energy dispersive X-ray spectroscopy (EDS) are used to analyze deposited clads in terms of elemental composition and flow characteristics in the deposition melt pool. Melt pool disturbance is found to be a vital parameter in determining the surface roughness of the final part. An inverse relation between the mean surface disturbance of the melt pool and the surface roughness of the part is observed, and carrier gas flow rate and powder mass flow rate both affect the overall melt pool size. The work has implications for the selection of process parameters for commercial laser deposition processes-the speed with which powder is delivered to the melt pool as well as the mass flow rate may need to be taken into account when calculating build rate and for a good surface finish requiring minimum post process finishing a stable melt pool may actually be the worst situation.

AB - Despite considerable advances in of laser direct metal deposition (LDMD) process optimization, there is rather limited work reported on the effects of melt pool variables on the final deposit characteristics. This article considers the effects of process parameters and melt pool characteristics on the deposition of Inconel 718 powder on a Ti-6Al-4V thin wall. A 1.5kW diode laser and LDMD system is used to produce a series of deposits. Images of the process are captured using Cu-vapor laser illumination and a high speed camera with long range microscopy optics, and quantitative results are extracted via image analysis. Process parameters such as carrier gas flow rate, powder mass flow rate and laser operating mode (CW and pulsed) and in process variables such as quantified melt pool disturbance, and final part characteristics are correlated and discussed. Scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and energy dispersive X-ray spectroscopy (EDS) are used to analyze deposited clads in terms of elemental composition and flow characteristics in the deposition melt pool. Melt pool disturbance is found to be a vital parameter in determining the surface roughness of the final part. An inverse relation between the mean surface disturbance of the melt pool and the surface roughness of the part is observed, and carrier gas flow rate and powder mass flow rate both affect the overall melt pool size. The work has implications for the selection of process parameters for commercial laser deposition processes-the speed with which powder is delivered to the melt pool as well as the mass flow rate may need to be taken into account when calculating build rate and for a good surface finish requiring minimum post process finishing a stable melt pool may actually be the worst situation.

KW - Cladding

KW - Deposition

KW - Laser

KW - Inconel

KW - Ti-6Al-4 V

U2 - 10.1080/10426914.2010.480999

DO - 10.1080/10426914.2010.480999

M3 - Journal article

VL - 25

SP - 1372

EP - 1380

JO - Materials and Manufacturing Processes

JF - Materials and Manufacturing Processes

SN - 1042-6914

IS - 12

ER -