Controlling interdependent meso-nanosecond dynamics and defect generation in metal 3D printing

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.

• UD
  U.S. Department of Energy

  Award: DE-AC02-06CH11357
• WS
  Washington State University

  Award: DE-NA0002442
• NN
  National Nuclear Security Administration

  Award: DE-NA0002442
• AN
  Argonne National Laboratory
• LL
  Lawrence Livermore National Laboratory

  Awards: 17-ERD-042, DE-AC52-07NA27344, 18-SI-003