Pore evolution mechanisms during directed energy deposition additive manufacturing

Kai Zhang (), Yunhui Chen, Sebastian Marussi, Xianqiang Fan, Maureen Fitzpatrick, Shishira Bhagavath, Marta Majkut, Bratislav Lukic, Kudakwashe Jakata, Alexander Rack, Martyn A. Jones, Junji Shinjo, Chinnapat Panwisawas, Chu Lun Alex Leung and Peter D. Lee ()
Additional contact information
Kai Zhang: University College London
Yunhui Chen: University College London
Sebastian Marussi: University College London
Xianqiang Fan: University College London
Maureen Fitzpatrick: University College London
Shishira Bhagavath: University College London
Marta Majkut: ESRF—The European Synchrotron
Bratislav Lukic: ESRF—The European Synchrotron
Kudakwashe Jakata: ESRF—The European Synchrotron
Alexander Rack: ESRF—The European Synchrotron
Martyn A. Jones: Rolls-Royce plc
Junji Shinjo: Shimane University
Chinnapat Panwisawas: Queen Mary University of London
Chu Lun Alex Leung: University College London
Peter D. Lee: University College London

Nature Communications, 2024, vol. 15, issue 1, 1-14

Abstract: Abstract Porosity in directed energy deposition (DED) deteriorates mechanical performances of components, limiting safety-critical applications. However, how pores arise and evolve in DED remains unclear. Here, we reveal pore evolution mechanisms during DED using in situ X-ray imaging and multi-physics modelling. We quantify five mechanisms contributing to pore formation, migration, pushing, growth, removal and entrapment: (i) bubbles from gas atomised powder enter the melt pool, and then migrate circularly or laterally; (ii) small bubbles can escape from the pool surface, or coalesce into larger bubbles, or be entrapped by solidification fronts; (iii) larger coalesced bubbles can remain in the pool for long periods, pushed by the solid/liquid interface; (iv) Marangoni surface shear flow overcomes buoyancy, keeping larger bubbles from popping out; and (v) once large bubbles reach critical sizes they escape from the pool surface or are trapped in DED tracks. These mechanisms can guide the development of pore minimisation strategies.

Date: 2024
References: View references in EconPapers View complete reference list from CitEc
Citations:

Downloads: (external link)
https://www.nature.com/articles/s41467-024-45913-9 Abstract (text/html)

Related works:
This item may be available elsewhere in EconPapers: Search for items with the same title.

Export reference: BibTeX RIS (EndNote, ProCite, RefMan) HTML/Text

Persistent link: https://EconPapers.repec.org/RePEc:nat:natcom:v:15:y:2024:i:1:d:10.1038_s41467-024-45913-9

Ordering information: This journal article can be ordered from
https://www.nature.com/ncomms/

DOI: 10.1038/s41467-024-45913-9

Access Statistics for this article

Nature Communications is currently edited by Nathalie Le Bot, Enda Bergin and Fiona Gillespie

More articles in Nature Communications from Nature
Bibliographic data for series maintained by Sonal Shukla () and Springer Nature Abstracting and Indexing ().