Effect of layer thickness on spatters oxidation of Hastelloy X alloy during powder bed fusion-laser beam processing
Journal article, 2023

This study investigates the impact of powder layer thickness on spatter generation and oxidation behavior during the processing of Hastelloy X. In-situ monitoring using optical tomography reveals that thicker powder layers result in a higher number of hot spatters generated during laser-melt-powder interaction. Scanning electron microscopy and Auger electron spectroscopy analysis demonstrate the presence of different types of spatters that oxidize differently depending on their origin. X-ray photoelectron spectroscopy analysis further shows that the surface enrichment of oxide-forming elements such as Al, Ti, Cr, and Fe varies with the type of spatter particle. Additionally, depth profile analysis using X-ray photoelectron spectroscopy indicates that the average oxide layer thickness increases from ∼2.5 nm in virgin to ∼68 nm in spatters generated at 150 μm powder layer thickness. The findings suggest that powder layer thickness is a crucial factor in controlling spatter generation and oxidation behavior during powder bed fusion-laser beam processing.

Oxidation

XPS

AES

In-situ monitoring

Spatters formation

Author

Ahmad Raza

Chalmers, Industrial and Materials Science, Materials and manufacture

Claudia de Andrade Schwerz

Chalmers, Industrial and Materials Science, Materials and manufacture

Camille Nicole Géraldine Pauzon

Chalmers, Industrial and Materials Science, Materials and manufacture

Grenoble Alpes University

Lars Nyborg

Chalmers, Industrial and Materials Science, Materials and manufacture

Eduard Hryha

Chalmers, Industrial and Materials Science, Materials and manufacture

Powder Technology

0032-5910 (ISSN) 1873-328X (eISSN)

Vol. 422 118461

Additive Manufacturing using Metal Pilot Line (MANUELA)

European Commission (EC) (EC/H2020/820774), 2018-10-01 -- 2022-09-30.

Subject Categories

Manufacturing, Surface and Joining Technology

Materials Chemistry

Other Physics Topics

Areas of Advance

Materials Science

DOI

10.1016/j.powtec.2023.118461

More information

Latest update

4/13/2023