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State-of-the-art metal 3D printers promise to revolutionize manufacturing, yet they have not reached optimal operational reliability. The challenge is to control complex laser–powder–melt pool interdependency (dependent upon each other) dynamics. We used high-fidelity simulations, coupled with synchrotron experiments, to capture fast multitransient dynamics at the meso-nanosecond scale and discovered new spatter-induced defect formation mechanisms that depend on the scan strategy and a competition between laser shadowing and expulsion. We derived criteria to stabilize the melt pool dynamics and minimize defects. This will help improve build reliability.
This article was first featured at https://ift.tt/3beWURc on May 7, 2020 at 02:14PM by Khairallah, S. A., Martin, A. A., Lee, J. R. I., Guss, G., Calta, N. P., Hammons, J. A., Nielsen, M. H., Chaput, K., Schwalbach, E., Shah, M. N., Chapman, M. G., Willey, T. M., Rubenchik, A. M., Anderson, A. T., Wang, Y. M., Matthews, M. J., King, W. E.
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