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Basic Mechanism of Surface Topography Evolution in Electron Beam Based Additive Manufacturing.

Christoph Breuning¹, Julian Pistor², Matthias Markl¹

¹Chair of Materials Science and Engineering for Metals, Friedrich-Alexander-Universität Erlangen-Nürnberg, Martensstr. 5, 91058 Erlangen, Germany.

Materials (Basel, Switzerland)

|July 27, 2022

Summary

This study reveals how meltpool dynamics in electron beam additive manufacturing (E-PBF) create surface topography. Understanding material transport mechanisms helps prevent surface bulges in 3D printed parts.

Keywords:

additive manufacturing electron beam heat transfer process modeling processing window topography

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Area of Science:

Materials Science
Manufacturing Engineering
Surface Science

Background:

Surface topography is a critical quality indicator in electron beam additive manufacturing (E-PBF).
Existing models often lack a fundamental understanding of the underlying physical mechanisms driving surface evolution during the E-PBF process.

Purpose of the Study:

To elucidate the fundamental mechanism governing surface topography evolution in E-PBF.
To link meltpool dynamics to characteristic surface morphologies and topographies.
To identify process parameters influencing surface bulge formation.

Main Methods:

Development and verification of a semi-analytical heat conduction model.
Analysis of spatio-temporal meltpool evolution.
Segmentation of the build surface into persistent meltpool domains.
Investigation of material transport mechanisms (evaporation, thermocapillary convection).

Main Results:

Persistent meltpool domains exhibit distinct surface morphologies and topographies.
Material transport, driven by evaporation and thermocapillary convection, dictates topography evolution.
This mechanism is responsible for the upper process window limit and surface bulge formation in E-PBF.

Conclusions:

A fundamental mechanism for surface topography evolution in E-PBF, driven by meltpool dynamics and material transport, has been identified and verified.
The proposed mechanism explains the formation of surface bulges at the upper process window limit.
Process strategies can be developed based on this mechanism to mitigate surface defects for complex geometries.