Pore elimination mechanisms during 3D printing of metals

S. Mohammad H. Hojjatzadeh, Niranjan D. Parab, Wentao Yan, Qilin Guo, Lianghua Xiong, Cang Zhao, Minglei Qu, Luis I. Escano, Xianghui Xiao, Kamel Fezzaa, Wes Everhart, Tao Sun () and Lianyi Chen ()
Additional contact information
S. Mohammad H. Hojjatzadeh: Missouri University of Science and Technology
Niranjan D. Parab: Argonne National Laboratory
Wentao Yan: National University of Singapore
Qilin Guo: Missouri University of Science and Technology
Lianghua Xiong: Missouri University of Science and Technology
Cang Zhao: Argonne National Laboratory
Minglei Qu: Missouri University of Science and Technology
Luis I. Escano: Missouri University of Science and Technology
Xianghui Xiao: Argonne National Laboratory
Kamel Fezzaa: Argonne National Laboratory
Wes Everhart: Department of Energy’s Kansas City National Security Campus Managed by Honeywell FM&T
Tao Sun: Argonne National Laboratory
Lianyi Chen: Missouri University of Science and Technology

Nature Communications, 2019, vol. 10, issue 1, 1-8

Abstract: Abstract Laser powder bed fusion (LPBF) is a 3D printing technology that can print metal parts with complex geometries without the design constraints of traditional manufacturing routes. However, the parts printed by LPBF normally contain many more pores than those made by conventional methods, which severely deteriorates their properties. Here, by combining in-situ high-speed high-resolution synchrotron x-ray imaging experiments and multi-physics modeling, we unveil the dynamics and mechanisms of pore motion and elimination in the LPBF process. We find that the high thermocapillary force, induced by the high temperature gradient in the laser interaction region, can rapidly eliminate pores from the melt pool during the LPBF process. The thermocapillary force driven pore elimination mechanism revealed here may guide the development of 3D printing approaches to achieve pore-free 3D printing of metals.

Date: 2019
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DOI: 10.1038/s41467-019-10973-9

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