Critical instability at moving keyhole tip generates porosity in laser melting

Zhao, Cang; Parab, Niranjan D.; Li, Xuxiao; Fezzaa, Kamel; Tan, Wenda; Rollett, Anthony D.; Sun, Tao

doi:10.1126/science.abd1587

Critical instability at moving keyhole tip generates porosity in laser melting

Journal Article · Wed Nov 25 23:00:00 EST 2020 · Science

DOI:https://doi.org/10.1126/science.abd1587· OSTI ID:1724317

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Department of Mechanical Engineering, Tsinghua University, Beijing 100084, China., Key Laboratory for Advanced Materials Processing Technology, Ministry of Education, Beijing 100084, China.
X-ray Science Division, Argonne National Laboratory, Lemont, IL 60439, USA.
Department of Mechanical Engineering, University of Utah, Salt Lake City, UT 84112, USA.
Department of Materials Science and Engineering, Carnegie Mellon University, Pittsburgh, PA 15213, USA., NextManufacturing Center, Carnegie Mellon University, Pittsburgh, PA 15213, USA.
Department of Materials Science and Engineering, University of Virginia, Charlottesville, VA 22904, USA.

Laser powder bed fusion is a dominant metal 3D printing technology. However, porosity defects remain a challenge for fatigue-sensitive applications. Some porosity is associated with deep and narrow vapor depressions called keyholes, which occur under high-power, low–scan speed laser melting conditions. High-speed x-ray imaging enables operando observation of the detailed formation process of pores in Ti-6Al-4V caused by a critical instability at the keyhole tip. We found that the boundary of the keyhole porosity regime in power-velocity space is sharp and smooth, varying only slightly between the bare plate and powder bed. The critical keyhole instability generates acoustic waves in the melt pool that provide additional yet vital driving force for the pores near the keyhole tip to move away from the keyhole and become trapped as defects.

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Sponsoring Organization:: USDOE

OSTI ID:: 1724317

Alternate ID(s):: OSTI ID: 1837057

Journal Information:: Science, Journal Name: Science Journal Issue: 6520 Vol. 370; ISSN 0036-8075

Publisher:: American Association for the Advancement of Science (AAAS)Copyright Statement

Country of Publication:: United States

Language:: English

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