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Pore evolution mechanisms during directed energy deposition additive manufacturing

Author

Listed:
  • Kai Zhang

    (University College London
    Research Complex at Harwell, Harwell Campus)

  • Yunhui Chen

    (University College London
    Research Complex at Harwell, Harwell Campus
    ESRF—The European Synchrotron
    RMIT University)

  • Sebastian Marussi

    (University College London
    Research Complex at Harwell, Harwell Campus)

  • Xianqiang Fan

    (University College London
    Research Complex at Harwell, Harwell Campus)

  • Maureen Fitzpatrick

    (University College London
    ESRF—The European Synchrotron)

  • Shishira Bhagavath

    (University College London
    Research Complex at Harwell, Harwell Campus)

  • Marta Majkut

    (ESRF—The European Synchrotron)

  • Bratislav Lukic

    (ESRF—The European Synchrotron)

  • Kudakwashe Jakata

    (ESRF—The European Synchrotron
    Harwell Campus)

  • Alexander Rack

    (ESRF—The European Synchrotron)

  • Martyn A. Jones

    (Rolls-Royce plc)

  • Junji Shinjo

    (Shimane University)

  • Chinnapat Panwisawas

    (Queen Mary University of London)

  • Chu Lun Alex Leung

    (University College London
    Research Complex at Harwell, Harwell Campus)

  • Peter D. Lee

    (University College London
    Research Complex at Harwell, Harwell Campus)

Abstract

Porosity in directed energy deposition (DED) deteriorates mechanical performances of components, limiting safety-critical applications. However, how pores arise and evolve in DED remains unclear. Here, we reveal pore evolution mechanisms during DED using in situ X-ray imaging and multi-physics modelling. We quantify five mechanisms contributing to pore formation, migration, pushing, growth, removal and entrapment: (i) bubbles from gas atomised powder enter the melt pool, and then migrate circularly or laterally; (ii) small bubbles can escape from the pool surface, or coalesce into larger bubbles, or be entrapped by solidification fronts; (iii) larger coalesced bubbles can remain in the pool for long periods, pushed by the solid/liquid interface; (iv) Marangoni surface shear flow overcomes buoyancy, keeping larger bubbles from popping out; and (v) once large bubbles reach critical sizes they escape from the pool surface or are trapped in DED tracks. These mechanisms can guide the development of pore minimisation strategies.

Suggested Citation

  • 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.
    • Handle: RePEc:nat:natcom:v:15:y:2024:i:1:d:10.1038_s41467-024-45913-9
    DOI: 10.1038/s41467-024-45913-9
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    References listed on IDEAS

    as
    1. Zhengtao Gan & Orion L. Kafka & Niranjan Parab & Cang Zhao & Lichao Fang & Olle Heinonen & Tao Sun & Wing Kam Liu, 2021. "Universal scaling laws of keyhole stability and porosity in 3D printing of metals," Nature Communications, Nature, vol. 12(1), pages 1-8, December.
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    3. Minglei Qu & Qilin Guo & Luis I. Escano & Ali Nabaa & S. Mohammad H. Hojjatzadeh & Zachary A. Young & Lianyi Chen, 2022. "Publisher Correction: Controlling process instability for defect lean metal additive manufacturing," Nature Communications, Nature, vol. 13(1), pages 1-1, December.
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    5. Yuze Huang & Tristan G. Fleming & Samuel J. Clark & Sebastian Marussi & Kamel Fezzaa & Jeyan Thiyagalingam & Chu Lun Alex Leung & Peter D. Lee, 2022. "Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing," Nature Communications, Nature, vol. 13(1), pages 1-11, December.
    6. Minglei Qu & Qilin Guo & Luis I. Escano & Ali Nabaa & S. Mohammad H. Hojjatzadeh & Zachary A. Young & Lianyi Chen, 2022. "Controlling process instability for defect lean metal additive manufacturing," Nature Communications, Nature, vol. 13(1), pages 1-8, December.
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