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Defects and anomalies in powder bed fusion metal additive manufacturing

https://doi.org/10.1016/j.cossms.2021.100974

Mostafaei, Amir ; Zhao, Cang ; He, Yining ; Reza Ghiaasiaan, Seyed ; Shi, Bo ; Shao, Shuai ; Shamsaei, Nima ; Wu, Ziheng ; Kouraytem, Nadia ; Sun, Tao ; et al ( April 2022 , Current Opinion in Solid State and Materials Science)

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Solidification crack propagation and morphology dependence on processing parameters in AA6061 from ultra-high-speed x-ray visualization

https://doi.org/https://doi.org/10.1016/j.addma.2021.101959

Kouraytem, Nadia ; Chiang, Po-Ju ; Jiang, Runbo ; Kantzos, Christopher ; Pauza, Joseph ; Cunningham, Ross ; Wu, Ziheng ; Tang, Guannan ; Parab, Niranjan ; Zhao, Cang ; et al ( June 2021 , Additive manufacturing)
null (Ed.)
Solidification or hot cracks are commonly observed defects in a number of metal alloys and may lead to deterioration of additively manufactured parts quality. In this study, ultra-high-speed x-ray radiography experiments enable the observation and characterization of bundles of hot-cracks that form in monobloc AA6061 substrate. The crack bundles are related to meltpool characteristics and pore formation. Crack propagation rate is also presented for the case of a crack that initiates from a pore. Two types of relevant pore formation are also described, namely keyhole porosity and crack-remelting porosity. The results of this study are expected to facilitate the validation of theoretical and numerical models of solidification cracking.
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