Defects and anomalies in powder bed fusion metal additive manufacturing

A Mostafaei, C Zhao, Y He, SR Ghiaasiaan… - Current Opinion in Solid …, 2022 - Elsevier
Metal additive manufacturing is a disruptive technology that is revolutionizing the
manufacturing industry. Despite its unrivaled capability for directly fabricating metal parts …

In-situ monitoring of sub-surface and internal defects in additive manufacturing: A review

Y AbouelNour, N Gupta - Materials & Design, 2022 - Elsevier
Abstract Additive Manufacturing (AM), or 3D printing, processes depend on a user-defined
set of optimized process parameters to create a component. Monitoring and control of AM …

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

Y Huang, TG Fleming, SJ Clark, S Marussi… - Nature …, 2022 - nature.com
Keyhole porosity is a key concern in laser powder-bed fusion (LPBF), potentially impacting
component fatigue life. However, some keyhole porosity formation mechanisms, eg, keyhole …

Critical instability at moving keyhole tip generates porosity in laser melting

C Zhao, ND Parab, X Li, K Fezzaa, W Tan, AD Rollett… - Science, 2020 - science.org
Laser powder bed fusion is a dominant metal 3D printing technology. However, porosity
defects remain a challenge for fatigue-sensitive applications. Some porosity is associated …

Dynamics of pore formation during laser powder bed fusion additive manufacturing

AA Martin, NP Calta, SA Khairallah, J Wang… - Nature …, 2019 - nature.com
Laser powder bed fusion additive manufacturing is an emerging 3D printing technique for
the fabrication of advanced metal components. Widespread adoption of it and similar …

Keyhole threshold and morphology in laser melting revealed by ultrahigh-speed x-ray imaging

R Cunningham, C Zhao, N Parab, C Kantzos, J Pauza… - Science, 2019 - science.org
We used ultrahigh-speed synchrotron x-ray imaging to quantify the phenomenon of vapor
depressions (also known as keyholes) during laser melting of metals as practiced in additive …

In-situ measurement and monitoring methods for metal powder bed fusion: an updated review

M Grasso, A Remani, A Dickins… - Measurement …, 2021 - iopscience.iop.org
The possibility of using a variety of sensor signals acquired during metal powder bed fusion
processes, to support part and process qualification and for the early detection of anomalies …

In-situ experimental and high-fidelity modeling tools to advance understanding of metal additive manufacturing

L Wang, Q Guo, L Chen, W Yan - International Journal of Machine Tools …, 2023 - Elsevier
Metal additive manufacturing has seen extensive research and rapidly growing applications
for its high precision, efficiency, flexibility, etc. However, the appealing advantages are still …

In-situ monitoring plume, spattering behavior and revealing their relationship with melt flow in laser powder bed fusion of nickel-based superalloy

Y Wang, W Guo, Y **e, H Li, C Zeng, M Xu… - Journal of Materials …, 2024 - Elsevier
Laser powder bed fusion (LPBF) is a highly dynamic and complex physical process, and
single-track defects tend to accumulate into non-negligible internal defects of parts. The …