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

SA Khairallah, AA Martin, JRI Lee, G Guss, NP Calta… - Science, 2020 - science.org
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 …

[HTML][HTML] Pore elimination mechanisms during 3D printing of metals

SMH Hojjatzadeh, ND Parab, W Yan, Q Guo… - Nature …, 2019 - nature.com
Laser powder bed fusion (LPBF) is a 3D printing technology that can print metal parts with
complex geometries without the design constraints of traditional manufacturing routes …

Revealing melt flow instabilities in laser powder bed fusion additive manufacturing of aluminum alloy via in-situ high-speed X-ray imaging

Q Guo, M Qu, LI Escano, SMH Hojjatzadeh… - International Journal of …, 2022 - Elsevier
Laser metal additive manufacturing technologies enable the fabrication of geometrically and
compositionally complex parts unachievable by conventional manufacturing methods …

[HTML][HTML] In situ X-ray imaging of defect and molten pool dynamics in laser additive manufacturing

CLA Leung, S Marussi, RC Atwood, M Towrie… - Nature …, 2018 - nature.com
The laser–matter interaction and solidification phenomena associated with laser additive
manufacturing (LAM) remain unclear, slowing its process development and optimisation …

[HTML][HTML] Ultrafast dynamics of laser-metal interactions in additive manufacturing alloys captured by in situ X-ray imaging

AA Martin, NP Calta, JA Hammons, SA Khairallah… - Materials Today …, 2019 - Elsevier
Advanced in situ characterization is essential for determining the underlying dynamics of
laser-material interactions central to both laser welding and the rapidly expanding field of …

[HTML][HTML] Universal scaling laws of keyhole stability and porosity in 3D printing of metals

Z Gan, OL Kafka, N Parab, C Zhao, L Fang… - Nature …, 2021 - nature.com
Abstract Metal three-dimensional (3D) printing includes a vast number of operation and
material parameters with complex dependencies, which significantly complicates process …

[HTML][HTML] Dynamics of pore formation during laser powder bed fusion additive manufacturing

AA Martin, NP Calta, SA Khairallah, J Wang… - Nature …, 2019 - nature.com
Laser powder bed fusion additive manufacturing is an emerging 3D printing technique for
the fabrication of advanced metal components. Widespread adoption of it and similar …

[HTML][HTML] Controlling process instability for defect lean metal additive manufacturing

M Qu, Q Guo, LI Escano, A Nabaa… - Nature …, 2022 - nature.com
The process instabilities intrinsic to the localized laser-powder bed interaction cause the
formation of various defects in laser powder bed fusion (LPBF) additive manufacturing …

Laser‐induced keyhole defect dynamics during metal additive manufacturing

AM Kiss, AY Fong, NP Calta, V Thampy… - Advanced …, 2019 - Wiley Online Library
Laser powder bed fusion (LPBF) metal additive manufacturing provides distinct advantages
for aerospace and biomedical applications. However, widespread industrial adoption is …

Bulk-explosion-induced metal spattering during laser processing

C Zhao, Q Guo, X Li, N Parab, K Fezzaa, W Tan… - Physical Review X, 2019 - APS
Spattering has been a problem in metal processing involving high-power lasers, like laser
welding, machining, and recently, additive manufacturing. Limited by the capabilities of in …