Laser melting modes in metal powder bed fusion additive manufacturing

Zhao, Cang; Shi, Bo; Chen, Shuailei; Du, Dong; Sun, Tao; Simonds, Brian J.; Fezzaa, Kamel; Rollett, Anthony D.

doi:10.1103/revmodphys.94.045002

Laser melting modes in metal powder bed fusion additive manufacturing

Journal Article · Thu Oct 20 00:00:00 EDT 2022 · Reviews of Modern Physics

DOI:https://doi.org/10.1103/revmodphys.94.045002· OSTI ID:2404973

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Tsinghua Univ., Beijing (China); Ministry of Education, Beijing (China). Key Laboratory for Advanced Materials Processing Technology
Univ. of Virginia, Charlottesville, VA (United States)
National Inst. of Standards and Technology (NIST), Boulder, CO (United States). Physical Measurements Laboratory
Argonne National Laboratory (ANL), Argonne, IL (United States)
Carnegie Mellon Univ., Pittsburgh, PA (United States)

In laser powder bed fusion additive manufacturing of metals, extreme thermal conditions create many highly dynamic physical phenomena such as vaporization and recoil, Marangoni convection, and protrusion and keyhole instability. Collectively however, the full set of phenomena is too complicated for practical applications and, in reality, the melting modes are used as a guideline for printing. With increasing local material temperature beyond the boiling point, the mode can change from conduction to keyhole. These mode designations ignore laser-matter interaction details but in many cases are adequate to determine the approximate microstructures and hence the properties of the build. To date, no consistent, common, and coherent definitions have been agreed upon because of historic limitations in melt pool and vapor depression morphology measurements. Here, we distinguish process-based definitions of different melting modes from those based on postmortem evidence. The latter are mainly derived from the transverse cross-sections of the fusion zone, whereas the former come directly from time-resolved x-ray imaging of melt pool and vapor depression morphologies. These process-based definitions are more strict and physically sound, and they offer new guidelines for laser additive manufacturing practices and create new research directions. Further, we highlight the significance of the keyhole, which substantially enhances the laser energy absorption by the melt pool. Recent studies strongly suggest that stable-keyhole laser melting enables efficient, sustainable, and robust additive manufacturing. The realization of this scenario demands the development of multiphysics models, signal translations from morphology to other feasible signals, and in-process metrology across platforms and scales.

View Accepted Manuscript (DOE)

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

Sponsoring Organization:: USDOE Office of Science (SC), Basic Energy Sciences (BES)

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 2404973

Journal Information:: Reviews of Modern Physics, Journal Name: Reviews of Modern Physics Journal Issue: 4 Vol. 94; ISSN 0034-6861

Publisher:: American Physical Society (APS)Copyright Statement

Country of Publication:: United States

Language:: English

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