Harmonizing sound and light: X-ray imaging unveils acoustic signatures of stochastic inter-regime instabilities during laser melting

Milad Hamidi Nasab (), Giulio Masinelli (), Charlotte Formanoir, Lucas Schlenger, Steven Petegem (), Reza Esmaeilzadeh, Kilian Wasmer, Ashish Ganvir, Antti Salminen, Florian Aymanns, Federica Marone, Vigneashwara Pandiyan, Sneha Goel and Roland E. Logé
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Milad Hamidi Nasab: École polytechnique fédérale de Lausanne (EPFL)
Giulio Masinelli: Swiss Federal Laboratories for Materials Science and Technology (Empa)
Charlotte Formanoir: École polytechnique fédérale de Lausanne (EPFL)
Lucas Schlenger: École polytechnique fédérale de Lausanne (EPFL)
Steven Petegem: Photon Science Division, Paul Scherrer Institut, PSI
Reza Esmaeilzadeh: École polytechnique fédérale de Lausanne (EPFL)
Kilian Wasmer: Swiss Federal Laboratories for Materials Science and Technology (Empa)
Ashish Ganvir: University of Turku
Antti Salminen: University of Turku
Florian Aymanns: École polytechnique Fédérale de Lausanne (EPFL)
Federica Marone: Paul Scherrer Institute
Vigneashwara Pandiyan: Swiss Federal Laboratories for Materials Science and Technology (Empa)
Sneha Goel: Photon Science Division, Paul Scherrer Institut, PSI
Roland E. Logé: École polytechnique fédérale de Lausanne (EPFL)

Nature Communications, 2023, vol. 14, issue 1, 1-14

Abstract: Abstract Laser powder bed fusion (LPBF) is a metal additive manufacturing technique involving complex interplays between vapor, liquid, and solid phases. Despite LPBF’s advantageous capabilities compared to conventional manufacturing methods, the underlying physical phenomena can result in inter-regime instabilities followed by transitions between conduction and keyhole melting regimes — leading to defects. We investigate these issues through operando synchrotron X-ray imaging synchronized with acoustic emission recording, during the remelting processes of LPBF-produced thin walls, monitoring regime changes occurring under constant laser processing parameters. The collected data show an increment in acoustic signal amplitude when switching from conduction to keyhole regime, which we correlate to changes in laser absorptivity. Moreover, a full correlation between X-ray imaging and the acoustic signals permits the design of a simple filtering algorithm to predict the melting regimes. As a result, conduction, stable keyhole, and unstable keyhole regimes are identified with a time resolution of 100 µs, even under rapid transitions, providing a straightforward method to accurately detect undesired processing regimes without the use of artificial intelligence.

Date: 2023
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DOI: 10.1038/s41467-023-43371-3

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