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

Research output: Contribution to Journal/Magazine › Journal article › peer-review

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Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing. / Huang, Yuze; Fleming, Tristan G.; Clark, Samuel J. et al.
In: Nature Communications, Vol. 13, No. 1, 1170, 04.03.2022.

Research output: Contribution to Journal/Magazine › Journal article › peer-review

Harvard

Huang, Y, Fleming, TG, Clark, SJ, Marussi, S, Fezzaa, K, Thiyagalingam, J, Leung, CLA & Lee, PD 2022, 'Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing', Nature Communications, vol. 13, no. 1, 1170. https://doi.org/10.1038/s41467-022-28694-x

APA

Huang, Y., Fleming, T. G., Clark, S. J., Marussi, S., Fezzaa, K., Thiyagalingam, J., Leung, C. L. A., & Lee, P. D. (2022). Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing. Nature Communications, 13(1), Article 1170. https://doi.org/10.1038/s41467-022-28694-x

Vancouver

Huang Y, Fleming TG, Clark SJ, Marussi S, Fezzaa K, Thiyagalingam J et al. Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing. Nature Communications. 2022 Mar 4;13(1):1170. doi: 10.1038/s41467-022-28694-x

Author

Huang, Yuze ; Fleming, Tristan G. ; Clark, Samuel J. et al. / Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing. In: Nature Communications. 2022 ; Vol. 13, No. 1.

Bibtex

@article{f1b5f03b3f0440549be67a9b401151ce,
title = "Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing",
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.",
author = "Yuze Huang and Fleming, {Tristan G.} and Clark, {Samuel J.} and Sebastian Marussi and Kamel Fezzaa and Jeyan Thiyagalingam and Leung, {Chu Lun Alex} and Lee, {Peter D.}",
year = "2022",
month = mar,
day = "4",
doi = "10.1038/s41467-022-28694-x",
language = "English",
volume = "13",
journal = "Nature Communications",
issn = "2041-1723",
publisher = "Nature Publishing Group",
number = "1",

}

RIS

TY - JOUR

T1 - Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing

AU - Huang, Yuze

AU - Fleming, Tristan G.

AU - Clark, Samuel J.

AU - Marussi, Sebastian

AU - Fezzaa, Kamel

AU - Thiyagalingam, Jeyan

AU - Leung, Chu Lun Alex

AU - Lee, Peter D.

PY - 2022/3/4

Y1 - 2022/3/4

N2 - 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.

AB - 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.

U2 - 10.1038/s41467-022-28694-x

DO - 10.1038/s41467-022-28694-x

M3 - Journal article

C2 - 35246522

VL - 13

JO - Nature Communications

JF - Nature Communications

SN - 2041-1723

IS - 1

M1 - 1170

ER -