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In Situ Elimination of Pores During Laser Powder Bed Fusion of Ti–6.5Al–3.5Mo–l.5Zr–0.3Si Titanium Alloy

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Acta Metallurgica Sinica (English Letters) Aims and scope

Abstract

The printing quality of components manufactured using laser powder bed fusion (LPBF) generally depends on the presence of various defects such as massive porosity. Thus, the efficient elimination of pores is an important factor in the production of a sound LPBF product. In this study, the efficacy of two in situ laser remelting approaches to eliminating pores during the LPBF of a titanium alloy Ti–6.5Al–3.5Mo–l.5Zr–0.3Si (TC11) was assessed both experimentally and computationally. These two remelting methods are surface remelting and layer-by-layer printing and remelting. A multi-track multi-layer phenomenological model was established to analyze the variation of pores with the temperature and velocity fields. The results showed that surface remelting with a high laser power, such as 180 W, can effectively eliminate pores within three deposited layers. However, such remelting could not reach defects in deeper regions. Layer-by-layer remelting with a 180 W laser could effectively eliminate the pores formed in the previous layer in real time. The results obtained in this study can provide useful guidance for the in situ control of printing defects supported by real-time monitoring, feedback, and operating systems of an intelligent LPBF equipment.

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Acknowledgements

This work was financially supported by the Development of a Verification Platform for Product Design, Process, and the Information Exchange Standards in Additive Manufacturing (No. 2019-00899-1-1), the National Key Research and Development Program of China (No. 2017YFB1103000), the National Natural Science Foundation of China (No. 51775281), and the Natural Science Foundation of Jiangsu Province (No. BK20180483).

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Authors and Affiliations

  1. School of Mechanical Engineering, Nanjing University of Science and Technology, Nanjing, 210094, China

    Ling Zhang, Wen-He Liao, Ting-Ting Liu, Hui-Liang Wei & Chang-Chun Zhang

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  1. Ling Zhang
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  2. Wen-He Liao
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Correspondence to Wen-He Liao.

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Zhang, L., Liao, WH., Liu, TT. 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 Metall. Sin. (Engl. Lett.) 35, 439–452 (2022). https://doi.org/10.1007/s40195-021-01297-z

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