Home > Research > Publications & Outputs > Keyhole fluctuation and pore formation mechanis...

Electronic data

  • s41467-022-28694-x

    Final published version, 2.92 MB, PDF document

    Available under license: CC BY: Creative Commons Attribution 4.0 International License

Links

Text available via DOI:

View graph of relations

Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing

Research output: Contribution to Journal/MagazineJournal articlepeer-review

Published
  • Yuze Huang
  • Tristan G. Fleming
  • Samuel J. Clark
  • Sebastian Marussi
  • Kamel Fezzaa
  • Jeyan Thiyagalingam
  • Chu Lun Alex Leung
  • Peter D. Lee
Close
Article number1170
<mark>Journal publication date</mark>4/03/2022
<mark>Journal</mark>Nature Communications
Issue number1
Volume13
Publication StatusPublished
<mark>Original language</mark>English

Abstract

Keyhole porosity is a key concern in laser powder-bed fusion (LPBF), potentially impacting component fatigue life. However, some keyhole porosity formation mechanisms, e.g., keyhole fluctuation, collapse and bubble growth and shrinkage, remain unclear. Using synchrotron X-ray imaging we reveal keyhole and bubble behaviour, quantifying their formation dynamics. The findings support the hypotheses that: (i) keyhole porosity can initiate not only in unstable, but also in the transition keyhole regimes created by high laser power-velocity conditions, causing fast radial keyhole fluctuations (2.5-10 kHz); (ii) transition regime collapse tends to occur part way up the rear-wall; and (iii) immediately after keyhole collapse, bubbles undergo rapid growth due to pressure equilibration, then shrink due to metal-vapour condensation. Concurrent with condensation, hydrogen diffusion into the bubble slows the shrinkage and stabilises the bubble size. The keyhole fluctuation and bubble evolution mechanisms revealed here may guide the development of control systems for minimising porosity.