Electromagnetic Churning of Laser Melt-Pool in Metal 3D Printing

Manufacturing flaws and microstructure irregularities pose challenges for the widespread adoption of metal additive manufacturing (MAM) in the US Army. These issues stem from the influence of melt-pool dynamics on the properties of 3D-printed metal parts, which are highly dependent on multiple process parameters. This paper investigates the potential of using electromagnetic fields (EM) to control the melt-pool dynamics in MAM, aiming to eliminate flaws and irregularities. A novel technique is proposed, involving a coil and strategically positioned permanent magnets to actively churn the melt pool. Initial validation of this approach was conducted using COMSOL Multiphysics® through simulation modeling, with ongoing efforts for experimental verification. The findings indicate promising opportunities for enhancing the consistency of 3D printed parts.

• Record URL:
  • https://doi.org/10.4271/2024-01-4095
• Availability:
  • Find a library where document is available. Order URL: http://worldcat.org/issn/01487191
• Supplemental Notes:
  • Abstract reprinted with permission of SAE International.
• Authors:
  • Karpenko, Oleksii
  • Udpa, Satish
  • Udpa, Lalita
  • Haq, Mahmood
• Conference:
  • 2024 NDIA Michigan Chapter Ground Vehicle Systems Engineering and Technology Symposium
  • Location: Novi Michigan, United States
  • Date: 2024-8-13 to 2024-8-15
• Publication Date: 2024-9-16

Language

• English

Media Info

• Media Type: Web
• Features: References;
• Serial:
  • SAE Technical Paper
  • Publisher: Society of Automotive Engineers (SAE)
  • ISSN: 0148-7191
  • EISSN: 2688-3627
  • Serial URL: http://papers.sae.org/

Subject/Index Terms

• TRT Terms: Additives; Computer aided design; Computer aided manufacturing; Magnetic materials; Manufacturing; Metals; Military vehicles; Nanotechnology
• Subject Areas: Highways; Vehicles and Equipment;

Filing Info

• Accession Number: 01930694
• Record Type: Publication
• Source Agency: SAE International
• Report/Paper Numbers: 2024-01-4095
• Files: TRIS, SAE
• Created Date: Sep 16 2024 4:14PM