In situ X-ray imaging of hot cracking and porosity during LPBF of Al-2139 with TiB2 additions and varied process parameters

• DOI: 10.1016/j.matdes.2023.112031
• Publication Date: 2023-06-06T06:00:10Z
• Authors: David T. Rees; Chu Lun Alex Leung; Joe Elambasseril; Sebastian Marussi; Saurabh Shah; Shashidhara Marathe; Milan Brandt; Mark Easton; Peter D. Lee
• Keywords: Volume fraction

Laser powder bed fusion (LPBF) additive manufacturing of 2XXX series Al alloys could be used for low volume specialist aerospace components, however, such exhibit hot cracking susceptibility that can lead to component failure. In this study, we show two approaches suppress the formation cracks by controlling solidification behaviour using: (1) TiB2 additions; and (2) optimisation LPBF process parameters. Using high-speed synchrotron X-ray radiography, monitored Al-2139 in situ, with without under a range conditions. situ radiography results captured crack growth over 1.0 ms at rate ca. 110 mm s−1, as well pore evolution, wetting build height. High-resolution computed tomography (sCT) was measure fraction defects, e.g. hydrogen pores microcracks, as-built samples. Our adding reduces up 79 % energy density 1000 5000 J mm−3, reducing average length, breadth, surface area cracks.