Investigating Powder Spreading Dynamics in Additive Manufacturing Processes by In-situ High-speed X-ray Imaging
The quality of the powder bed is known to be one of the main factors that influence the quality of the part being manufactured by powderbed- based additive manufacturing processes. For example, in the laser powder bed fusion process, it has been demonstrated that improving the powder bed density and homogeneity improves the final quality of the part. Understanding powder spreading dynamics in the powder-bed-based additive manufacturing processes is critical for designing spreading structures and spreading parameters, identifying defect formation mechanisms in the powder bed, and guiding the design of optimized feedstock powders. Extensive efforts have been devoted to understand the fundamental mechanism of the powder flow and spreading process. Various powder flow testers were used to study the flow behavior of powders used in additive manufacturing. However, the powder flow conditions in flow meters are different from those in real additive manufacturing conditions. Models have also been developed to simulate and study the spreading process. The discrete element method (DEM) is currently the main tool for computationally simulating the spreading process. However, these models are based on many physical assumptions. Visible light cameras have been used recently to conduct in-situ study of powder spreading in additive manufacturing. Due to the limited resolution and penetration depth of visible light, it is extremely difficulty to study the particle-scale powder spreading dynamics. Here, to overcome the challenges of studying powder spreading dynamics under real additive manufacturing conditions, we developed an experimental approach to study the particle-scale powder spreading process with high spatial and temporal resolution using the high-speed high-energy X-ray imaging facility at beamline 32-ID-B of the APS. Figure 1 shows an overview of the research setup. It is composed of a vacuum chamber (building environment), an automatic powder spreading system, a laser system, an X-ray source (X-ray outlet), and an X-ray detection/imaging system.