In situ monitoring of the melt pools in laser powder bed fusion (LPBF) has enabled the elucidation of process phenomena. There has been an increasing interest in also using melt pool monitoring to identify process anomalies and control the quality of...
Selective laser melting (SLM), a metal powder fusion additive manufacturing process, has the potential to manufacture complex components for aerospace and biomedical implants. Large-scale adaptation of these technologies is hampered due to the presen...
Anisotropic mechanical properties are a well-known issue in selective laser melted parts. The microstructure produced by selective laser melting (SLM) is directional, including the solidified melt pool structures and grains. This work investigates th...
Selective Laser Melting (SLM) is a popular additive manufacturing (AM) method where a laser beam selectively melts powder layer by layer based on the building geometry. The melt pool peak temperature during build process is an important parameter to...
A three dimensional finite element model (FEM) was established to simulate the temperature distribution, flow activity, and deformation of the melt pool of selective laser melting (SLM) AZ91D magnesium alloy powder. The latent heat in phase transitio...
To capture the complex metallic spatter and melt pool behavior during the rapid interaction between the laser and metal material, high-speed cameras are applied to record the laser powder bed fusion process and generate a large volume of image data....
Metal additive manufacturing (AM) works on the principle of consolidating feedstock material in layers towards the fabrication of complex objects through localized melting and resolidification using high-power energy sources. Powder bed fusion and di...
The following work presents the results of an investigation of the cause–effect relationship between the stability of a melt pool and the roughness of an inclined, unsupported steel surface that was 3D-printed using the laser powder bed fusion...
The rectangular spot laser cladding system, due to its large spot size and high efficiency, has been widely applied in laser cladding equipment, significantly improving cladding’s efficiency. However, while enhancing cladding efficiency, the re...
Wire-arc additive manufacturing (WAAM) is favored by the industry for its high material utilization rate and low cost. However, wire-arc additive manufacturing of lattice structures faces problems with forming accuracy such as broken rod and surface...
The continuous back-and-forth melting of the powder bed during the laser powder bed fusion (LPBF) process leads to the development of residual heat, which affects the melt pool geometry as the laser scan progresses. The magnitude of the residual heat...
In order to track the free interface of the melt pool and understand the evolution of the melt pool, the flow of fluid, and the interface behavior of gas and liquid, a physical model is developed by using the VOF method in this paper. Its characteris...
Direct laser deposition (DLD) requires high-energy input and causes poor stability and portability. To improve the deposited layer quality, conducting online measurements and feedback control of the dimensions, temperature, and other melt-pool parame...
By numerical simulation and experimental analysis, the melt pool shapes for the laser surface remelting of nickel-based single-crystal superalloy under different processing parameters are investigated. The results show that heat conduction and heat c...
In the laser powder bed fusion additive manufacturing process, the quality of fabrications is intricately tied to the laser–matter interaction, specifically the formation of the melt pool. This study experimentally examined the intricacies of m...
A coupled heat source model that combined a Gauss surface heat source with a Gauss cylindrical volumetric heat source was introduced to simulate temperature field distribution and melt pool characteristics using a finite element simulation (FEM) meth...
Electron beam selective melting is a metal powder bed fusion additive manufacturing technology. In order to study the temperature field and melt pool changes of high Nb-TiAl electron beam selective melting on a single scan line and multi-scan lines....
The quality stability and batch consistency of laser powder bed fusion products are key issues that must be solved in additive manufacturing. The melt pool radiation intensity data of laser powder bed fusion contain a significant amount of forming pr...
In directed energy deposition (DED), accurately controlling and predicting melt pool characteristics is essential for ensuring desired material qualities and geometric accuracies. This paper introduces a robust surrogate model based on recurrent neur...
Laser Powder Bed Fusion (L-PBF) is one of the most widespread, versatile, and promising metal Additive Manufacturing (AM) techniques. L-PBF allows for the manufacturing of geometrically complex parts with good surface characteristics. In this process...
The quality and characteristics of a powder in powder bed fusion processes play a vital role in the quality of additively manufactured components. Its characteristics may influence the process in various ways. This paper presents an investigation hig...
Powder-bed arc additive manufacturing (PBAAM) may reduce the cost of powder-bed metal additive manufacturing and enable thicker layers than laser powder bed fusion (LPBF), but melt-track stability limits are not well established. Here, 316L stainless...
Accurate melt pool geometry prediction is essential for ensuring quality and reliability in Laser Powder Bed Fusion (L-PBF). However, small experimental datasets and limited physical interpretability often restrict the effectiveness of traditional ma...
The growing number of commercially available machines for laser deposition welding show the growing acceptance and importance of this technology for industrial applications. Their increasing usage in research and production requires process stability...
Laser-based powder bed fusion of metals (PBF-LB/M) is one of the most promising additive manufacturing technologies to fabricate complex-structured metal parts. However, its corresponding applications have been limited by technical bottlenecks and in...
This paper investigates the effects on the material microstructure of varying the Inter-Layer Cooling Time (ILCT) during the printing process in laser powder bed fusion (L-PBF) multi-laser machines. Despite these machines allowing higher productivity...
The development and improvement of monitoring and process control systems is one of the important ways of advancing laser metal deposition (LMD). The control of hydrodynamic, heat and mass transfer processes in LMD is extremely important, since these...
Optical coherence tomography (OCT) is an inline process monitoring technology for laser welding with various applications in the pre-, in-, and post-process. In-process monitoring with OCT focuses on the measurement of weld depth by the placement of...
In this study, silver (Ag) and silver–diamond (Ag-D) composites with varying diamond (D) content are fabricated using laser powder bed fusion (L-PBF) additive manufacturing (AM). The L-PBF process parameters and inert gas flow rate are optimise...
A coupled discrete element method and computational fluid dynamics (DEM-CFD) approach was utilized to systematically investigate the mesoscale dynamics of single-track melt pools in laser powder bed fusion (LPBF) of TiAl-based composites. It was foun...
In additive manufacturing processes, the metal melt pool is decisive for processing quality. A single sensor is incapable of fully capturing its physical characteristics and is prone to data inaccuracies. This study proposes a multi-sensor monitoring...
A variety of techniques have been utilized in metal additive manufacturing (AM) for melt pool size management, including modeling and feed-forward approaches. In a few cases, closed-loop control has been demonstrated. In this research, closed-loop me...
Laser powder bed fusion (LPBF) is an advanced additive manufacturing method, but its productivity is relatively low, which limits its application. Performance can be increased without hardware modifications by enlarging the powder-layer thickness. Ho...
In the additive manufacturing laser powder bed fusion (L-PBF) process, the optimization of the print process parameters and the development of conduction zones in the laser power (P) and scanning speed (V) parameter spaces are critical to meeting pro...
An integral part of laser powder bed fusion (LPBF) quality control is identifying optimal process parameters tailored to each application, often achieved through time-consuming and costly experiments. Melt pool dynamics further complicate LPBF qualit...
Selective laser melting (SLM) is an additive manufacturing (AM) technique that has the potential to produce almost any three-dimensional (3D) metallic part, even those with complicated shapes. Throughout the SLM process, the heat transfer characteris...
A 2D model of laser melting consisting of heat transfer, hydrodynamic flow, surface tension, and a free surface motion was established. A physical field simulation of the laser melting process was performed, and the effect of steady magnetic field pa...
Selective laser melting is a commonly employed additive manufacturing technique that facilitates the fabrication of intricate geometries through the laser-induced melting of powder materials. The quality of the produced parts is significantly influen...
The melt-pool behaviors during selective laser melting (SLM) of Al2O3-reinforced and a eutectic mixture of Al2O3-ZrO2-reinforced AISI 304 stainless-steel composites were numerically analyzed and experimentally validated. The thermal analysis results...
Laser metal deposition (LMD) is a technology for the production of near-net-shape components. It is necessary to control the manufacturing process to obtain good geometrical accuracy and metallurgical properties. In the present study, a closed-loop c...
Selective laser melting (SLM) technology is a promising additive manufacturing technology. However, due to the numerous influencing factors in this complex process, a reliable real-time method is needed to monitor the forming process of SLM. The molt...
AlSi10Mg inclined struts with angle of 45° were fabricated by selective laser melting (SLM) using different scanning speed and hatch spacing to gain insight into the evolution of the molten pool morphology, surface roughness, and dimensional accuracy...
The melt pool calculating method is presented based on the solution of the heat conduction problem in a three-dimensional formulation, taking into account the latent heat of fusion and the change in thermophysical properties with temperature. In this...
In this study, regression-based machine learning models were developed to predict the melt pool width and depth formed during the Laser Powder Bed Fusion (LPBF) process for Fe-3.4Si and Fe-6Si alloys. Based on experimentally obtained melt pool width...
During the powder bed fusion of metals using a laser beam (PBF-LB/M), an inert atmosphere is maintained in the build chamber to avoid reactions of the liquid metal with ambient air leading to the creation of oxides or nitrides, which alter the mechan...
This paper presents the results of computational and physical studies on the production of corium and its retention in an MR’s melt trap of the Lava-B facility. A feature of the Lava-B facility used in the IAE NNC RK to study the processes occu...
Textured microstructures and anisotropic properties are key factors for the optimization of magnetic materials. Only for high texture grades can the remanence Jr and the maximum energy product (BH)max be maximized. In additive manufacturing such as l...
Laser powder bed fusion (LPBF) has a wide range of uses in high-tech industries, including the aerospace and biomedical fields. For LPBF, the flow of molten metal is crucial; until now, however, the flow in the melt pool has not been described thorou...
Humping is a common defect in direct energy deposition processes that reduces the geometric integrity of printed products. The available literature on humping detection is deemed reactive, as they focus on detecting late-stage melt pool spatial abnor...
In this study, a combined simulation and experimental approach is utilized to investigate the influence of hatch spacing on the microstructure and as-built quality of 316L stainless steel (SS) samples fabricated by selective laser melting (SLM). A th...
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