Bulk-Explosion-Induced Metal Spattering During Laser Processing

Zhao, Cang; Guo, Qilin; Li, Xuxiao; Parab, Niranjan; Fezzaa, Kamel; Tan, Wenda; Chen, Lianyi; Sun, Tao

doi:10.1103/PhysRevX.9.021052

Title: Bulk-Explosion-Induced Metal Spattering During Laser Processing

Journal Article · Fri Jun 14 00:00:00 EDT 2019 · Physical Review. X

DOI:https://doi.org/10.1103/PhysRevX.9.021052· OSTI ID:1526327

Zhao, Cang; Guo, Qilin; Li, Xuxiao; Parab, Niranjan; Fezzaa, Kamel; Tan, Wenda; Chen, Lianyi; Sun, Tao

Spattering has been a problem in metal processing involving high-power lasers, like laser welding, machining, and recently, additive manufacturing. Limited by the capabilities of in situ diagnostic techniques, typically imaging with visible light or laboratory x-ray sources, a comprehensive understanding of the laser-spattering phenomenon, particularly the extremely fast spatters, has not been achieved yet. In this work, using MHz single-pulse synchrotron-x-ray imaging, we probe the spattering behavior of Ti-6Al-4V with micrometer spatial resolution and subnanosecond temporal resolution. Combining direct experimental observations, quantitative image analysis, as well as numerical simulations, our study unravels a novel mechanism of laser spattering: The bulk explosion of a tonguelike protrusion forming on the front keyhole wall leads to the ligamentation of molten metal at the keyhole rims and the subsequent spattering. Our report confirms the critical role of melt and vapor flow in the laser-spattering process and opens a door to manufacturing spatter- and defect-free metal parts via precise control of keyhole dynamics.

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Research Organization:: Argonne National Laboratory (ANL), Argonne, IL (United States)

Sponsoring Organization:: National Science Foundation (NSF); USDOE Office of Science (SC)

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 1526327

Alternate ID(s):: OSTI ID: 1530389

Journal Information:: Physical Review. X, Journal Name: Physical Review. X Vol. 9 Journal Issue: 2; ISSN 2160-3308

Publisher:: American Physical SocietyCopyright Statement

Country of Publication:: United States

Language:: English

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Cited by: 81 works

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SUPERCONDUCTIVITY AND SUPERFLUIDITY
laser additive manufacturing
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Title: Bulk-Explosion-Induced Metal Spattering During Laser Processing

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