Dynamics of pore formation during laser powder bed fusion additive manufacturing

Martin, Aiden A.; Calta, Nicholas P.; Khairallah, Saad A.; Wang, Jenny; Depond, Phillip J.; Fong, Anthony Y.; Thampy, Vivek; Guss, Gabe M.; Kiss, Andrew M.; Stone, Kevin H.; Tassone, Christopher J.; Nelson Weker, Johanna; Toney, Michael F.; van Buuren, Tony; Matthews, Manyalibo J.

doi:10.1038/s41467-019-10009-2

Title: Dynamics of pore formation during laser powder bed fusion additive manufacturing

Journal Article · 30 April 2019 · Nature Communications

DOI: https://doi.org/10.1038/s41467-019-10009-2 · OSTI ID:1619474

Martin, Aiden A. ^[1]; Calta, Nicholas P. ^[1]; Khairallah, Saad A. ^[1]; Wang, Jenny ^[1]; Depond, Phillip J. ^[1]; Fong, Anthony Y. ^[2]; Thampy, Vivek ^[2]; Guss, Gabe M. ^[1]; Kiss, Andrew M. ^[2];

^[2]; Tassone, Christopher J. ^[2];

^[2];

^[2]; van Buuren, Tony ^[1]; Matthews, Manyalibo J. ^[1]

Lawrence Livermore National Lab. (LLNL), Livermore, CA (United States)
SLAC National Accelerator Lab., Menlo Park, CA (United States). Stanford Synchrotron Radiation Lightsource

Laser powder bed fusion additive manufacturing is an emerging 3D printing technique for the fabrication of advanced metal components. Widespread adoption of it and similar additive technologies is hampered by poor understanding of laser-metal interactions under such extreme thermal regimes. Here, we elucidate the mechanism of pore formation and liquid-solid interface dynamics during typical laser powder bed fusion conditions using in situ X-ray imaging and multi-physics simulations. Pores are revealed to form during changes in laser scan velocity due to the rapid formation then collapse of deep keyhole depressions in the surface which traps inert shielding gas in the solidifying metal. We develop a universal mitigation strategy which eliminates this pore formation process and improves the geometric quality of melt tracks. Our results provide insight into the physics of laser-metal interaction and demonstrate the potential for science-based approaches to improve confidence in components produced by laser powder bed fusion.

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Research Organization:: Lawrence Livermore National Laboratory (LLNL), Livermore, CA (United States); SLAC National Accelerator Laboratory (SLAC), Menlo Park, CA (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Energy Efficiency Office. Advanced Manufacturing Office; USDOE National Nuclear Security Administration (NNSA); USDOE Office of Science (SC), Basic Energy Sciences (BES)

Grant/Contract Number:: AC52-07NA27344; AC02-76SF00515

OSTI ID:: 1619474

Alternate ID(s):: OSTI ID: 1513151; OSTI ID: 1615145

Report Number(s):: LLNL-JRNL-754485; 940776

Journal Information:: Nature Communications, Vol. 10; ISSN 2041-1723

Publisher:: Nature Publishing GroupCopyright Statement

Country of Publication:: United States

Language:: English

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