Project Info


Simulated Laser-Based Additive Manufacturing Experiments to Evaluate Laser-Metal Interactions

Michael Kaufman | mkaufman@mines.edu

Additive manufacturing (AM) involves highly dynamic environments where a high energy power source, such as a laser, melts powder particles forming new layer after solidification. Variations in laser settings (scanning pattern, travel speed, and input power) can lead to large changes in laser-metal interactions (including the magnitude of heat absorption). Ultimately, these laser-metal interactions influence solidification conditions, microstructure, and mechanical properties of the AM build. This project is a collaboration with the National Institute for Standards and Technology (NIST), where NIST scientists measured the laser energy absorbed in the metal while obtaining X-ray images during solidification in microsecond intervals. The student will interact with Mines and NIST to help analyze the data and samples from these state-of-the-art experiments to help build a better understanding of laser-based additive manufacturing.

Publications on similar experiments can be found here:
https://doi.org/10.1103/PhysRevApplied.10.044061
https://doi.org/10.1016/j.procir.2018.08.065

Grand Challenge: Engineer the tools of scientific discovery

Student Preparation


Qualifications

The student should be interested in additive manufacturing. Experience with metallographic preparation, electron microscopy, image processing techniques, and/or Matlab software would be beneficial, but are not required.

Student is required to attend the basic lab safety training offered by Environmental Health and Safety at Mines.

Time Commitment

Time commitment is flexible and can be varied throughout the semester. Approximately 4-5 hours per week, on average, is supported by the MURF, and is the baseline needed to be able to make significant progress on a project. Should the student have interest in additional work beyond 4-5 hours per week, funding through CANFSA may be available for additional hours, up to 20 per week.

Skills/Techniques Gained

This project will provide a student the opportunity to develop a wide range of skills that will be useful for graduate school or a career in industry. Depending on the student’s interest area, skills can be developed in metallographic preparation, scanning electron microscopy (SEM), electron backscatter diffraction (EBSD), and processing of transmission X-ray microscopy images.

Mentoring Plan

The faculty mentor will meet regularly with the student, and in addition, the student will interact with graduate students and faculty in CANFSA on a weekly basis. Realistic goals will be set at the beginning of the project, and they will be continuously updated as needed. The frequent interaction with Mines professors and graduate students will ensure all resources are being provided to ensure the student gets the most out of the project. The student will also be able to interact with scientists at NIST over the course of the project.