Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing

King, Wayne E.; Barth, Holly D.; Castillo, Victor M.; Gallegos, Gilbert F.; Gibbs, John W.; Hahn, Douglas E.; Kamath, Chandrika; Rubenchik, Alexander M.

doi:10.1016/j.jmatprotec.2014.06.005

Observation of keyhole-mode laser melting in laser powder-bed fusion additive manufacturing

Journal Article · Wed Jun 25 00:00:00 EDT 2014 · Journal of Materials Processing Technology

DOI:https://doi.org/10.1016/j.jmatprotec.2014.06.005· OSTI ID:1502044

^[1]; Barth, Holly D. ^[2]; Castillo, Victor M. ^[2]; Gallegos, Gilbert F. ^[2]; Gibbs, John W. ^[3]; Hahn, Douglas E. ^[2]; Kamath, Chandrika ^[4]; Rubenchik, Alexander M. ^[5]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States). Physical and Life Sciences Directorate
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States). Engineering Directorate
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States). Physical and Life Sciences Directorate; Northwestern Univ., Evanston, IL (United States). Dept. of Materials Science and Engineering
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States). Computations Directorate
Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States). NIF and Photon Science Directorate

Laser powder-bed fusion additive manufacturing of metals employs high-power focused laser beams. Typically, the depth of the molten pool is controlled by conduction of heat in the underlying solid material. But, under certain conditions, the mechanism of melting can change from conduction to so-called “keyhole-mode” laser melting. In this mode, the depth of the molten pool is controlled by evaporation of the metal. Keyhole-mode laser melting results in melt pool depths that can be much deeper than observed in conduction mode. In addition, the collapse of the vapor cavity that is formed by the evaporation of the metal can result in a trail of voids in the wake of the laser beam. In this paper, the experimental observation of keyhole-mode laser melting in a laser powder-bed fusion additive manufacturing setting for 316L stainless steel is presented. Finally, the conditions required to transition from conduction controlled melting to keyhole-mode melting are identified.

View Accepted Manuscript (DOE)

Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA); USDOE Office of Science (SC), Basic Energy Sciences (BES) (SC-22)

Grant/Contract Number:: AC52-07NA27344; FC52-08NA28752; AC02-05CH11231

OSTI ID:: 1502044

Alternate ID(s):: OSTI ID: 1524740

Report Number(s):: LLNL-JRNL--642426; 762014

Journal Information:: Journal of Materials Processing Technology, Journal Name: Journal of Materials Processing Technology Journal Issue: 12 Vol. 214; ISSN 0924-0136

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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