In-situ observation of melt pool phenomena in directed energy deposition of iron ore andaluminum materials

• This study reports on the high-speed imaging investigation possibilities of laser beammaterialsurface interaction when processing Fe2O3-Al powders and an Fe2O3 powder-AlSI5wire combination in directed energy deposition. In-situ observation of various melt poolphenomena and exothermic reaction behavior of the material systems using high-speed imagingwas at the focus of this research work. Depending on the feed material arrangement (powderpowderor powder-wire) and process parameters, significant differences in the melt poolformation were observed, including melt pool separation into two distinct phases and theoccurrence of thermite reaction at different stages of the process. In addition to that, theinfluence of feed materials and laser power on the thermite reaction time was discussed in detail,showing their dissimilar behavior. During laser processing of the powder-powder arrangement,the reaction duration increased with the increase of laser power, whereas the powder-wireconfiguration demonstrated the opposite trend, most likely due to the smaller surface contactarea, developed between the iron ore particles and the AlSi5 wire. Chemical composition,morphological appearances and phase accumulation were analyzed using scanning electronmicroscopy and energy-dispersive X-ray spectroscopy. The obtained data were used toestablish a connection between the melt pool and the reaction products. High-speed imagingwas utilized throughout the experiments to observe and capture the process phenomena.

Subject headings

TEKNIK OCH TEKNOLOGIER  -- Materialteknik -- Bearbetnings-, yt- och fogningsteknik (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Materials Engineering -- Manufacturing, Surface and Joining Technology (hsv//eng)

TEKNIK OCH TEKNOLOGIER  -- Materialteknik -- Metallurgi och metalliska material (hsv//swe)

ENGINEERING AND TECHNOLOGY  -- Materials Engineering -- Metallurgy and Metallic Materials (hsv//eng)

Publication and Content Type

ref (subject category)

art (subject category)