A PRESENTATION ON MELTING

POOL BEHAVIOR

Joni Chandra Dhar

1/15/2020
 MELTING POOL MONITORING SYSTEM

1. Optical set-up:
• high-speed near-infrared (NIR) thermal CMOS camera
• a photodiode
2. Data Processing Unit:
• calculate melt pool area or other parameters from the image frames and is
part of the hardware set-up together with the optical set-up.
• the processed data will be evaluated and compared to reference data
generated by this unit.
3. Reference data:
• reference data is the expected sensor value of the melt pool.
4. Quality estimation:
• interpretation of the signals is done and compared to the reference data
• This is the most important software component
• This unit estimates the quality and presents it in a map for each layer
• can measure melt pool intensity, length, width, area
Fig: A schematic overview of monitoring system [a]
MELTING POOL MONITORING SYSTEM

Fig: Optical set-up of the monitoring system [a]

 MELTING POOL MONITORING SYSTEM

• The implementation of a monitoring system demands full

access to the machine’s hardware and software.
• The inhouse developed SLM machine of KU Leuven was therefore equipped with this
set-up.
• This machine distinguishes
itself from commercial machines, by its in-house developed machine control system,
besides the full access to the
hardware.
 EFFECT OF SCAN STRATEGY

 melting pool looks normal at scanning speed of

800 mm/s
 the improvement in ductility using a low
scanning speed was attributed to the delay in
crack initiation and propagation by decreasing
the residual defects and melting pool boundaries.
 while irregular melting pools with multiple
boundaries were observed at scanning speed of
1000 mm/s.
 the observed melting pool boundaries at high
scanning speed increased the probability of brittle
feature fracture, where crack nucleation and
propagation occur.
Fig: SEM images of the melting pool morphology at scanning speeds of 800 mm/s (a, c) and 1000 mm/s (b, d) [b]
 EFFECT OF LASER POWER

(a) P= 50 W
Width = 99 μm
Penetration = 9.6 μm
1. Length = 149 μm

(b) P= 200 W
Width = 168 μm
Penetration = 46 μm
Length = 393 μm

Fig: Effect of laser power on melting pool shape [c]

 EFFECT OF SCAN VELOCITY

(a) V= 50 mm/s
Width = 240 μm
Penetration = 80 μm
Length = 379 μm

(b) V= 250 mm/s

Width = 108 μm
Penetration = 16.7 μm
Length = 282 μm

Fig: Effect of laser scan velocity on melting pool shape [c]

TEMPERATURE PROFILE IN MELTING
POOL

Fig: temperature profile in x-y plane at time t= 0.56, 1.12, 1.68, 2.24 µs [c]
POROSITY IN MELTING POOL

Fig: effect of processing parameters on porosity [d]

 POROSITY IN MELTING POOL

Keyhole porosity
 Reduce power
 Increase scan velocity
 No effect of hatch distance and layer thickness
 Scan strategy in L shape track
 Effect of power is greater than scan velocity
 Boundary should be considered as a large zone of uncertainty
than sharp boundary
Lack of diffusion porosity
 Depends on hatch distance, layer thickness and scan strategy
 DEVELOPMENT OF KEYHOLE
POROSITY

Fig: time-lapse synchrotron imaging of a melt pool under static laser [e]
 REFERENCE

a) Clijsters, S., Craeghs, T., Buls, S., Kempen, K., & Kruth, J. (2014). In situ quality control of the
selective laser melting process using a high-speed, real-time melt pool monitoring system. The
International Journal of Advanced Manufacturing Technology, 75(5-8), 1089-1101.
doi:10.1007/s00170-014-6214-8
b) Liu, J., Song, Y., Chen, C., Wang, X., Li, H., Zhou, C., . . . Sun, J. (2020). Effect of scanning
speed on the microstructure and mechanical behavior of 316L stainless steel fabricated by
selective laser melting. Materials & Design, 186, 108355. doi:10.1016/j.matdes.2019.108355
c) Li, Y., Zhou, K., Tor, S. B., Chua, C. K., & Leong, K. F. (2017). Heat transfer and phase transition
in the selective laser melting process. International Journal of Heat and Mass Transfer, 108,
2408-2416. doi:10.1016/j.ijheatmasstransfer.2017.01.093
d) Oliveira, J., Lalonde, A., & Ma, J. (2020). Processing parameters in laser powder bed fusion metal
additive manufacturing. Materials & Design, 193, 108762. doi:10.1016/j.matdes.2020.108762
e) Cunningham, R., Zhao, C., Parab, N., Kantzos, C., Pauza, J., Fezzaa, K., . . . Rollett, A. D. (2019).
Keyhole threshold and morphology in laser melting revealed by ultrahigh-speed x-ray imaging.
Science, 363(6429), 849-852. doi:10.1126/science.aav4687