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Dynamics of pore formation during laser powder bed fusion additive manufacturing

Author

Listed:
  • Aiden A. Martin

    (Lawrence Livermore National Laboratory)

  • Nicholas P. Calta

    (Lawrence Livermore National Laboratory)

  • Saad A. Khairallah

    (Lawrence Livermore National Laboratory)

  • Jenny Wang

    (Lawrence Livermore National Laboratory)

  • Phillip J. Depond

    (Lawrence Livermore National Laboratory)

  • Anthony Y. Fong

    (SLAC National Accelerator Laboratory)

  • Vivek Thampy

    (SLAC National Accelerator Laboratory)

  • Gabe M. Guss

    (Lawrence Livermore National Laboratory)

  • Andrew M. Kiss

    (SLAC National Accelerator Laboratory)

  • Kevin H. Stone

    (SLAC National Accelerator Laboratory)

  • Christopher J. Tassone

    (SLAC National Accelerator Laboratory)

  • Johanna Nelson Weker

    (SLAC National Accelerator Laboratory)

  • Michael F. Toney

    (SLAC National Accelerator Laboratory)

  • Tony Buuren

    (Lawrence Livermore National Laboratory)

  • Manyalibo J. Matthews

    (Lawrence Livermore National Laboratory)

Abstract

Laser powder bed fusion additive manufacturing is an emerging 3D printing technique for the fabrication of advanced metal components. Widespread adoption of it and similar additive technologies is hampered by poor understanding of laser-metal interactions under such extreme thermal regimes. Here, we elucidate the mechanism of pore formation and liquid-solid interface dynamics during typical laser powder bed fusion conditions using in situ X-ray imaging and multi-physics simulations. Pores are revealed to form during changes in laser scan velocity due to the rapid formation then collapse of deep keyhole depressions in the surface which traps inert shielding gas in the solidifying metal. We develop a universal mitigation strategy which eliminates this pore formation process and improves the geometric quality of melt tracks. Our results provide insight into the physics of laser-metal interaction and demonstrate the potential for science-based approaches to improve confidence in components produced by laser powder bed fusion.

Suggested Citation

  • Aiden A. Martin & Nicholas P. Calta & Saad A. Khairallah & Jenny Wang & Phillip J. Depond & Anthony Y. Fong & Vivek Thampy & Gabe M. Guss & Andrew M. Kiss & Kevin H. Stone & Christopher J. Tassone & J, 2019. "Dynamics of pore formation during laser powder bed fusion additive manufacturing," Nature Communications, Nature, vol. 10(1), pages 1-10, December.
    • Handle: RePEc:nat:natcom:v:10:y:2019:i:1:d:10.1038_s41467-019-10009-2
    DOI: 10.1038/s41467-019-10009-2
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    Cited by:

    1. Paromita Nath & Sankaran Mahadevan, 2023. "Probabilistic predictive control of porosity in laser powder bed fusion," Journal of Intelligent Manufacturing, Springer, vol. 34(3), pages 1085-1103, March.
    2. Kai Zhang & Yunhui Chen & Sebastian Marussi & Xianqiang Fan & Maureen Fitzpatrick & Shishira Bhagavath & Marta Majkut & Bratislav Lukic & Kudakwashe Jakata & Alexander Rack & Martyn A. Jones & Junji S, 2024. "Pore evolution mechanisms during directed energy deposition additive manufacturing," Nature Communications, Nature, vol. 15(1), pages 1-14, December.

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