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  4. Toward Architected Microstructures Using Advanced Laser Beam Shaping in Laser Powder Bed Fusion of Ti-6al-4v
 
research article

Toward Architected Microstructures Using Advanced Laser Beam Shaping in Laser Powder Bed Fusion of Ti-6al-4v

Esmaeilzadeh, Reza  
•
Jhabvala, Jamasp  
•
Schlenger, Lucas  
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April 24, 2025
Advanced Functional Materials

Laser Powder Bed Fusion (LPBF) stations mostly use lasers with a Gaussian beam intensity distribution, as it has advantages like small divergence and high ability to be focused. This distribution creates significant thermal gradients leading to high cooling rates, which promote the formation of an alpha'-martensitic structure in Ti-6Al-4V. While this microstructure offers high strength, it sacrifices ductility, necessitating post-processing heat treatments to decompose the alpha'-martensite into an alpha+beta lamellar structure. However, these post-treatments are time-consuming, and notably transform the part microstructure in a uniform way. In this study, an advanced laser beam shaping module, based on a liquid crystals on silicon-spatial light modulator (LCoS-SLM) is employed, to customize the intensity distribution and reduce the cooling rate with appropriate processing parameters. Thermal camera monitoring, along with finite element modeling (FEM), confirmed a significant reduction in the cooling rate for the tailored beam, compared to the Gaussian profile. This technique is implemented in the LPBF process, resulting in specimens with a mixture of lamellar alpha+beta and alpha'-martensitic structures site specifically. Beam shaping is thereby shown to provide new degrees of freedom for fine-tuning of microstructures at the melt pool scale, and for LPBF building of 3D architected microstructures.

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Type
research article
DOI
10.1002/adfm.202420427
Web of Science ID

WOS:001473293200001

Author(s)
Esmaeilzadeh, Reza  

École Polytechnique Fédérale de Lausanne

Jhabvala, Jamasp  

École Polytechnique Fédérale de Lausanne

Schlenger, Lucas  

École Polytechnique Fédérale de Lausanne

van der Meer, Mathijs  

École Polytechnique Fédérale de Lausanne

Boillat, Eric  

École Polytechnique Fédérale de Lausanne

Cayron, Cyril  

École Polytechnique Fédérale de Lausanne

Jamili, Amir Mohammad  

École Polytechnique Fédérale de Lausanne

Xiao, Junfeng  

École Polytechnique Fédérale de Lausanne

Loge, Roland E.  

École Polytechnique Fédérale de Lausanne

Date Issued

2025-04-24

Publisher

WILEY-V C H VERLAG GMBH

Published in
Advanced Functional Materials
Subjects

architected microstructure

•

beam shaping

•

laser powder bed fusion

•

numerical simulation

•

thermal monitoring

•

Ti-6Al-4 V

Editorial or Peer reviewed

REVIEWED

Written at

EPFL

EPFL units
LMTM  
FunderFunding(s)Grant NumberGrant URL

Swiss National Science Foundation (SNSF)

CRSII5_193799

SMARTAM project, part of the Strategic Focus Area Advanced Manufacturing (SFA-AM) initiative of the ETH Board in Switzerland

PX Group to the Thermomechanical Metallurgy Laboratory (LMTM) at EPFL

Available on Infoscience
May 6, 2025
Use this identifier to reference this record
https://infoscience.epfl.ch/handle/20.500.14299/249867
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