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Home » News

Research demonstrated potential of EHLA in alloy development

News By AM Chronicle EditorFebruary 9, 20225 Mins Read
Potential of EHLA in Rapid Alloy development
The in-situ powder supply of the EHLA process have Aachen researchers hopeful that it will prove beneficial in Rapid Alloy Development (Courtesy RWTH DAP/Irrmischer)
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Researchers from RWTH Aachen University’s RWTH Aachen Chair for Digital Additive Production (DAP) studied the viability of employing Extreme High-Speed Laser Material Deposition Process (EHLA) for effectively screening and developing novel alloys for Laser Beam Powder Bed Fusion (PBF-LB).

The results showed potential transferability across the processes manufacturing outputs by comparing process variables such as laser intensity and the resulting microstructures.

More from the Study 

EHLA and PBF-LB procedures differ primarily in powder supply systems and locations of laser energy input. The powder is deposited worldwide in one layer in Laser Beam Powder Bed Fusion, and the laser point is concentrated on this surface. The powder is delivered locally through a nozzle in the Extreme High-Speed Laser Material Deposition Process, and the powder focus is slightly above the deposition surface (approx. 1 mm); this allows various alloys to be carried and independently mixed in-situ before deposition.

Despite being the most widely used Additive Manufacturing method, researchers were concerned that the promise of PBF-LB was not being fully realized because to the time- and material-intensive alloy creation process. Aachen researchers discovered and analyzed the important EHLA and PBF-LB process factors that impact cooling rates and subsequent microstructures in order to accelerate this process. They next applied their findings to X30Mn22, a high-manganese steel. The microstructures of either sample were compared as the final stage in this procedure to assess process transferability.

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Comparisons

Because the intensity of the energy input into the powder material has a significant influence on the cooling rate, the interaction time between the powder and laser beam, as well as the energy input into the material (i.e., laser intensity at laser spot), are calculated and compared for both processes.

Taking laser power and laser spot diameter (spot) into consideration, it was discovered that the intensity in PBF-LB is about fourteen times more than in EHLA; nevertheless, the interaction period between material and laser beam in PBF-LB and EHLA differs by a factor of ten. As a result, it is expected that the effects of the various laser intensities are successfully balanced off, resulting in a comparable energy input per particle.

The researchers also investigated the effect of EHLA process speed on cooling rate. To do this, the dendritic arm spacings (DAS) produced by each method were measured and compared. The DAS is lowered from 1.29 m to 0.58 m by raising the EHLA process speed from 50 to 150 m/min, suggesting that the cooling rate in EHLA is primarily reliant on the process speed.

EHLA LPBF Comparison

A shows an EHLA melt pool in light microscope micrograph at a magnification of 100x; B shows a PBF-LB melt pool in LOM micrograph at 500x (Courtesy RWTH DAP)

Another variable studied was energy volume density (Ev), which may be utilized to compare the process features of laser power, scanning speed, and powder mass flow rate in terms of thermal balance. The predicted Ev for PBF-LB is approximately 2.3 times that of EHLA. The predicted Ev for PBF-LB, on the other hand, only corresponds to a molten material mass of a single layer thickness. Because the actual depth of molten material in the PBF-LB process is twice or three times the layer thickness, the Ev must be raised proportionately. As a result, the researchers believe that the heat balance in both processes is comparable.

Further examination into the varied melt pool properties, geometry, and size reveals that the geometry of the EHLA melt pool measures a 25 times bigger area than the geometry of the PBF-LB melt pool. Furthermore, the melt pool morphologies differ; the EHLA melt pool is flatter than the PBF-LB melt pool. This is mostly owing to the different forms of energy input into the material by the two processes, as well as heat loss from the melt pool into the substrate or the layers below.

Promising initial results

The researchers discovered that the microstructure of the manufactured samples is dendritic in both methods, and that the resultant dendrite arm spacings (DAS) are comparable and may be aligned further by adjusting process parameters such as process speed in EHLA. As a consequence, it may be inferred that the resultant microstructures and mechanical characteristics for EHLA and PBF-LB are equivalent.

Further research will be conducted to compare the chemical contents of the produced samples acquired through the two procedures. EHLA process factors such as particle velocity and powder mass flow will also be investigated in terms of their impact on the chemical characteristics of the resultant samples. Furthermore, the evaporation behavior of several alloys will be explored and compared owing to differences in energy input.

In summary, the researchers concluded that, in terms of microstructural characteristics, EHLA is suitable as an advanced alloy screening and development technique for PBF-LB.

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Original Source

3d printing additive manufacturing EHLA Germany PBF-LB Powder Bed Fusion rapid alloy
AM Chronicle Editorial Team

The AM Chronicle Editorial Team is a collective of passionate individuals committed to delivering insightful, accurate and engaging stories to additive manufacturing audiences worldwide.

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