In situ X-ray imaging of defect and molten pool dynamics in laser additive manufacturing

Chu Lun Alex Leung (), Sebastian Marussi, Robert C. Atwood, Michael Towrie, Philip J. Withers and Peter D. Lee ()
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Chu Lun Alex Leung: The University of Manchester
Sebastian Marussi: The University of Manchester
Robert C. Atwood: Diamond Light Source Ltd, Diamond House, Harwell Science & Innovation Campus
Michael Towrie: Central Laser Facility, Research Complex at Harwell, Science & Technology Facilities Council, Rutherford Appleton Laboratory
Philip J. Withers: The University of Manchester
Peter D. Lee: The University of Manchester

Nature Communications, 2018, vol. 9, issue 1, 1-9

Abstract: Abstract The laser–matter interaction and solidification phenomena associated with laser additive manufacturing (LAM) remain unclear, slowing its process development and optimisation. Here, through in situ and operando high-speed synchrotron X-ray imaging, we reveal the underlying physical phenomena during the deposition of the first and second layer melt tracks. We show that the laser-induced gas/vapour jet promotes the formation of melt tracks and denuded zones via spattering (at a velocity of 1 m s−1). We also uncover mechanisms of pore migration by Marangoni-driven flow (recirculating at a velocity of 0.4 m s−1), pore dissolution and dispersion by laser re-melting. We develop a mechanism map for predicting the evolution of melt features, changes in melt track morphology from a continuous hemi-cylindrical track to disconnected beads with decreasing linear energy density and improved molten pool wetting with increasing laser power. Our results clarify aspects of the physics behind LAM, which are critical for its development.

Date: 2018
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Persistent link: https://EconPapers.repec.org/RePEc:nat:natcom:v:9:y:2018:i:1:d:10.1038_s41467-018-03734-7

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DOI: 10.1038/s41467-018-03734-7

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