同步辐射X-ray成像原位研究LPBF成形GH3536合金粉末飞溅行为

In Situ Study on Spatter Behavior of GH3536 Alloy Powders during Laser Powder Bed Fusion via Synchrotron X-ray Imaging

  • 摘要: 激光粉末床熔融(LPBF)技术因其优异的复杂结构成形能力而备受关注,但加工过程中的飞溅问题严重影响零件质量。本研究采用同步辐射X射线超快成像技术,实现了对GH3536镍基高温合金粉末LPBF过程飞溅行为的原位观测。结果表明,单层打印时存在金属粉末固体飞溅、金属射流飞溅、夹带熔化飞溅和粉末聚结飞溅等四种典型飞溅类型,同时在双层打印中观察到了飞溅重熔及缺陷形成过程;飞溅的形成受到熔池表面反冲压力和金属蒸气羽流的协同作用调控;成形件的表面粗糙度随激光扫描速度的增加,即激光能量密度的降低而增加,可通过调控LPBF工艺参数有效控制飞溅,改善成形件表面形貌。本研究为优化LPBF工艺参数、抑制飞溅产生提供了重要理论依据,对提升增材制造零件质量具有重要指导意义。

     

    Abstract: Laser powder bed fusion (LPBF) has garnered significant attention due to its exceptional capability in fabricating complex structures, yet spattering during processing severely compromises the part qualities. In this study, synchrotron radiation X-ray ultrafast imaging is used to achieve in-situ observation of spattering behavior during LPBF of GH3536 alloy. Four typical spattering types are identified and validated in single-layer printing, which are metal powder spattering, metal jet spattering, powder and melted powder spattering, and coalesced powder spattering, while spatter re-melting and defect formation are observed during double-layer printing. The forming of spattering is regulated by the synergistic effect of back-flushing pressure of the molten pool surface and metal steam plume. The surface roughness of the part prepared increases with the increase of the scanning speed of laser, and with the decrease of the laser energy density. The spattering can be regulated by adjusting the LPBF process parameters. This study provides critical theoretical insights for optimizing LPBF parameters and suppressing spatter generation, and offers significant guidance for improving the quality of additive manufactured components.

     

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