Controlling interdependent meso-nanosecond dynamics and defect generation in metal 3D printing.
basic_science · Level V
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- Record sourced from PubMed, PMID 32381724.
- Also identified by DOI 10.1126/science.aay7830.
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Abstract
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.