Page 31 - MSAM-3-3

Materials Science in Additive Manufacturing Defects in additively fabricated Al6061

Conflict of interest

Tuğrul Özel serves as the Editorial Board Member of the
journal, but did not in any way involve in the editorial and
peer-review process conducted for this paper, directly or
indirectly. Other authors declare they have no competing
interests.
Author contributions

Conceptualization: Sivaji Karna, Faik Derya Ince, Lang
Yuan, Tuğrul Özel
Data curation: Sivaji Karna, Tianyu Zhang, Andrew J.
Gross, Lang Yuan
Formal analysis: Sivaji Karna, Faik Derya Ince, Lang Yuan,
Tuğrul Özel
Figure 8. Optimum decision variables were identified using
optimization algorithms and initial experimental parameters Funding acquisition: Timothy Krentz, Dale Hitchcock
Abbreviations: h: Hatch distance; P: Power; V: Speed; MOGA: Multi- Investigation: Sivaji Karna, Faik Derya Ince
objective genetic algorithm Methodology: Sivaji Karna, Faik Derya Ince, Lang Yuan,
Tuğrul Özel
4. Conclusion Resources: Andrew J. Gross, Timothy Krentz, Dale
This study presents an experimental method for measuring Hitchcock, Lang Yuan
and quantifying defects, that is, porosity and cracks, on Software: Sivaji Karna, Faik Derya Ince, Tuğrul Özel
aluminum Al6061 alloy test cubes additively fabricated Supervision: Lang Yuan, Tuğrul Özel
using L-PBF. We adopted experimental models employed Validation: Sivaji Karna, Andrew J. Gross, Timothy Krentz,
in multi-objective optimization algorithms to determine Dale Hitchcock, Lang Yuan
the Pareto front of multiple fitness functions for relative Visualization: Sivaji Karna, Faik Derya Ince, Tuğrul Özel
porosity and relative crack density, that is, using MOGA or Writing—original draft preparation: Sivaji Karna, Faik
the Pareto search algorithm available in MATLAB Global Derya Ince, Tuğrul Özel
Optimization Toolbox. The optimum results for L-PBF Writing—review and editing: Lang Yuan, Tuğrul Özel
process parameters are reported to be 355 – 357 W for Ethics approval and consent to participate
P, 550 – 568 mm/s for v , and 0.21 mm for h, generating
s
minimum relative porosity and relative crack density of Not applicable
0.34 – 0.43% and 0.37 – 0.45%, respectively. We also discuss Consent for publication
the influence of hatching and platform temperature from
the defect quantification data on the resultant porosity and Not applicable
crack density. This balanced minimization of relative defect
densities is expected to reduce the negative effect on the Availability of data
mechanical properties of additively fabricated aluminum Data will be made available upon request.
alloy Al6061, addressing the solidification cracking issues
in L-PBF of aluminum alloys. References
1. Vafadar A, Guzzomi F, Rassau A, Hayward K. Advances
Acknowledgments in metal additive manufacturing: A review of common
Lang Yuan is grateful for the support of the Savannah processes, industrial applications, and current challenges.
River National Laboratory (SRNL). SRNL is operated by Appl Sci. 2021;11(3):1213.
Battelle Savannah River Alliance, LLC under Contract doi: 10.3390/app11031213
No. 89303321CEM000080 for the United States (US) 2. Yadroitsev I, Yadroitsava I, Du Plessis A, MacDonald E,
Department of Energy. editors. Fundamentals of Laser Powder Bed Fusion of Metals.
Amsterdam, Netherlands: Elsevier; 2021.
Funding
3. Özel T. A review on in-situ process sensing and monitoring
SRNL, Contract No. 89303321CEM000080, Receiver: Lang systems for fusion-based additive manufacturing. Int J
Yuan Mechatron Manuf Syst. 2023;16(2-3):115-154.

Volume 3 Issue 3 (2024) 13 doi: 10.36922/msam.3652