In-Situ Characterization of Pore Formation Dynamics in Pulsed Wave Laser Powder Bed Fusion

Hojjatzadeh, S. Mohammad H.; Guo, Qilin; Parab, Niranjan D.; Qu, Minglei; Escano, Luis I.; Fezzaa, Kamel; Everhart, Wes; Sun, Tao; Chen, Lianyi

doi:10.3390/ma14112936

In-Situ Characterization of Pore Formation Dynamics in Pulsed Wave Laser Powder Bed Fusion

Journal Article · Sat May 29 00:00:00 EDT 2021 · Materials

DOI:https://doi.org/10.3390/ma14112936· OSTI ID:1785300

; ; Parab, Niranjan D.; Qu, Minglei; Escano, Luis I.; ; ; Sun, Tao;

Laser powder bed fusion (LPBF) is an additive manufacturing technology with the capability of printing complex metal parts directly from digital models. Between two available emission modes employed in LPBF printing systems, pulsed wave (PW) emission provides more control over the heat input compared to continuous wave (CW) emission, which is highly beneficial for printing parts with intricate features. However, parts printed with pulsed wave LPBF (PW-LPBF) commonly contain pores, which degrade their mechanical properties. In this study, we reveal pore formation mechanisms during PW-LPBF in real time by using an in-situ high-speed synchrotron x-ray imaging technique. We found that vapor depression collapse proceeds when the laser irradiation stops within one pulse, resulting in occasional pore formation during PW-LPBF. We also revealed that the melt ejection and rapid melt pool solidification during pulsed-wave laser melting resulted in cavity formation and subsequent formation of a pore pattern in the melted track. The pore formation dynamics revealed here may provide guidance on developing pore elimination approaches.

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Research Organization:: Argonne National Laboratory (ANL); Kansas City Nuclear Security Campus (KCNSC), Kansas City, MO (United States)

Sponsoring Organization:: USDOE; USDOE Office of Science (SC)

Grant/Contract Number:: AC02-06CH11357; NA0002839

OSTI ID:: 1785300

Alternate ID(s):: OSTI ID: 1825646
OSTI ID: 1839046

Journal Information:: Materials, Journal Name: Materials Journal Issue: 11 Vol. 14; ISSN MATEG9; ISSN 1996-1944

Publisher:: MDPI AGCopyright Statement

Country of Publication:: Switzerland

Language:: English

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In-Situ Characterization of Pore Formation Dynamics in Pulsed Wave Laser Powder Bed Fusion

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