The Use of Sacrificial Graphite-like Coating to Improve Fusion Efficiency of Copper in Selective Laser Melting.

Thin and ultrathin carbon films reduce the laser energy required for copper powder fusion in selective laser melting (SLM). The low absorption of infrared (IR) radiation and its excellent thermal conductivity leads to an intricate combination of processing parameters to obtain high-quality printed parts in SLM. Two carbon-based sacrificial thin films were deposited onto copper to facilitate light absorption into the copper substrates. Graphite-like (3.5 µm) and ultra-thin (25 nm) amorphous carbon films were deposited by aerosol spraying and direct current magnetron sputtering, respectively. The melting was analyzed for several IR (1.06 µm) laser powers in order to observe the coating influence on the energy absorption. Scanning electron microscopy showed the topography and cross-section of the thermally affected area, electron backscatter diffraction provided the surface chemical composition of the films, and glow-discharge optical emission spectroscopy (GDOES) allowed the tracking of the in-deep chemical composition of the 3D printed parts using carbon film-covered copper. Ultra-thin films of a few tens of nanometers could reduce fusion energy by about 40%, enhanced by interferences phenomena. Despite the lower energy required, the melting maintained good quality and high wettability when using top carbon coatings. A copper part was SLM printed and associated with 25 nm of carbon deposition between two copper layers. The chemical composition analysis demonstrated that the carbon was intrinsically removed during the fusion process, preserving the high purity of the copper part.

Miniature laser powder bed fusion system for in situ synchrotron x-ray micro-computed tomography experiments at the European Synchrotron Radiation Facility.

We describe our miniature laser powder bed fusion (L-PBF) system for in situ synchrotron x-ray micro-computed tomography (XCT) at the European Synchrotron Radiation Facility. This replicator was designed to extend the characterization of L-PBF to 3D. This instrument fills in a technical gap because the existing replicators were mostly designed to shed light on the dynamic mechanisms involved in molten pool formation but, therefore, suffered from a lack of 3D information. Technical details regarding the setup and beamline integration are given. Experimental validations via post-mortem XCT scans and in situ scans acquired during experiments conducted at the BM05 beamline of the European Synchrotron Radiation Facility are provided. Based on a few illustrative examples, we show that such a replicator opens the path to collect key 3D information that to date could not be available. Our miniature instrument complements the other replicators developed in the world by other research groups that enable operando x-ray imaging (radiography) and operando x-ray diffraction.