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Updated: Jun 22, 2025

Fabrication and Characterization of Thickness Mode Piezoelectric Devices for Atomization and Acoustofluidics

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Exploring Piezoelectric Actuation towards Its Applications in Laser Powder Bed Fusion Additive Manufacturing.

Connor Griffin¹, Hanfei Mei¹, Sivaji Karna¹

¹Department of Mechanical Engineering, University of South Carolina, Columbia, SC 29208, USA.

Sensors (Basel, Switzerland)

|June 27, 2024

Summary

This study optimized ultrasonic wave propagation in laser powder bed fusion additive manufacturing using piezoelectric transducers. A thin plate fixture achieved 100% energy transmission, enhancing melt pool control and defect reduction.

Keywords:

additive manufacturing laser powder bed fusion melt pool morphology piezoelectric actuation ultrasound transmission

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Area of Science:

Materials Science
Mechanical Engineering
Additive Manufacturing

Background:

Piezoelectric materials convert mechanical strain into electrical charge, useful for actuation and sensing.
Ultrasonic actuators are emerging in additive manufacturing to control solidification and reduce defects.
Laser powder bed fusion (LPBF) is a key additive manufacturing technique.

Purpose of the Study:

To design and evaluate a fixture for optimizing ultrasonic wave propagation in LPBF.
To investigate the efficiency of piezoelectric transducers in transmitting ultrasonic energy through a build plate.
To assess the impact of ultrasound on melt pool morphology and defect formation during LPBF.

Main Methods:

Developed a fixture to integrate piezoelectric transducers with the LPBF build plate.
Tested three piezoelectric transducer implementations, measuring out-of-plane ultrasonic velocity transmission.
Conducted single-track laser scanning experiments to analyze melt pool morphology and defects.

Main Results:

A thin plate adhered to the piezoelectric transducer achieved 100% transmission of ultrasonic velocity and energy.
Preliminary analysis showed ultrasound influences solidification, affecting melt pool morphology and defects.
The optimized fixture design facilitates efficient ultrasonic wave propagation.

Conclusions:

The developed fixture and transducer configuration effectively enhance ultrasonic wave transmission for LPBF.
Ultrasonic application shows potential for improving alloy printability and reducing defects in additive manufacturing.
This work provides a foundation for in situ ultrasound testing for defect and texture detection in LPBF.