Zhang, Kai;
Bhagavath, Shishira;
Marussi, Sebastian;
Rack, Alexander;
Atwood, Robert;
Jones, Martyn A;
Leung, Chu Lun Alex;
... Lee, Peter D; + view all
(2025)
Pore-lean directed energy deposition additive manufacturing through laser power modulation.
Acta Materialia
, Article 121515. 10.1016/j.actamat.2025.121515.
(In press).
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Abstract
Directed energy deposition (DED) laser additive manufacturing (AM) is a promising technique for building complex components and performing repair applications. However, large defects can form through coalescence of argon bubbles from the feedstock powder, potentially reducing end-component mechanical performance. Here, we used correlative high-speed synchrotron X-ray and infrared imaging, coupled with multiphysics modelling to develop a strategy to control defect formation. We demonstrate that the bubble dynamics can be controlled by appropriately modulating the laser power, temporarily disrupting the Marangoni flow, enabling bubble release. The bubble control mechanisms discovered here provide a way to achieve defect-lean AM.
| Type: | Article |
|---|---|
| Title: | Pore-lean directed energy deposition additive manufacturing through laser power modulation |
| Open access status: | An open access version is available from UCL Discovery |
| DOI: | 10.1016/j.actamat.2025.121515 |
| Publisher version: | https://doi.org/10.1016/j.actamat.2025.121515 |
| Language: | English |
| Additional information: | Under a Creative Commons license https://creativecommons.org/licenses/by/4.0/ |
| UCL classification: | UCL UCL > Provost and Vice Provost Offices > UCL BEAMS UCL > Provost and Vice Provost Offices > UCL BEAMS > Faculty of Engineering Science > Dept of Mechanical Engineering |
| URI: | https://discovery.ucl.ac.uk/id/eprint/10214465 |
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