Revealing mechanisms of processing defect mitigation in laser powder bed fusion via shaped beams using high-speed X-ray imaging

Yuan, Jiandong; Guo, Qilin; Clark, Samuel J.; Escano, Luis I.; Nabaa, Ali; Qu, Minglei; Huang, Junye; Li, Qingyuan; Román, Allen Jonathan; Osswald, Tim A.; Fezzaa, Kamel; Chen, Lianyi

doi:10.1016/j.ijmachtools.2024.104232

Revealing mechanisms of processing defect mitigation in laser powder bed fusion via shaped beams using high-speed X-ray imaging

Journal Article · Sat Nov 15 23:00:00 EST 2025 · International Journal of Machine Tools and Manufacture

DOI:https://doi.org/10.1016/j.ijmachtools.2024.104232· OSTI ID:3004207

Yuan, Jiandong ^[1]; Guo, Qilin ^[1]; Clark, Samuel J. ^[2]; ^[1]; Nabaa, Ali ^[1]; Qu, Minglei ^[1]; Huang, Junye ^[1]; Li, Qingyuan ^[1]; ^[1]; Osswald, Tim A. ^[1]; Fezzaa, Kamel ^[2]; ^[1]

Univ. of Wisconsin, Madison, WI (United States)
Argonne National Laboratory (ANL), Argonne, IL (United States)

The laser powder bed fusion (LPBF) process utilizing a focused Gaussian-shaped beam faces challenges, including pore formation, melt pool fluctuation and liquid spattering. While beam shaping technology has been explored as a potential approach for defect mitigation, the beam-matter interaction dynamics during melting with shaped beams remain unclear. Here, we report the direct observation of ring-shaped beam-matter interaction dynamics, including pore formation, melt pool fluctuation and liquid spattering, and unveil defect mitigation mechanisms in ring-shaped beam laser powder bed fusion process. Here, we find that, by spatially manipulating incident laser rays, the ring-shaped beam controls keyhole morphology, thereby managing the distribution of the reflected rays. This manipulation can effectively eliminate the formation of an unstable cavity at the keyhole tip, stabilizing the keyhole and mitigating keyhole pores. This enhanced keyhole stability effectively reduces the melt pool fluctuation, the formation of liquid breakup induced spatters and liquid droplet colliding induced large spatters in the laser powder bed fusion process. Additionally, the high-energy forefront of the ring-shaped beam effectively melts the powder bed, reducing agglomeration liquid spatter in the laser powder bed fusion process. The discovered defect mitigation mechanisms may guide the design of beam shaping strategies for simultaneously increasing the quality and productivity of metal additive manufacturing.

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). Scientific User Facilities (SUF); National Science Foundation (NSF)

Grant/Contract Number:: AC02-06CH11357

OSTI ID:: 3004207

Alternate ID(s):: OSTI ID: 2478731

Journal Information:: International Journal of Machine Tools and Manufacture, Journal Name: International Journal of Machine Tools and Manufacture Vol. 204; ISSN 0890-6955

Publisher:: ElsevierCopyright Statement

Country of Publication:: United States

Language:: English

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