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Laser powder bed fusion (LPBF) holds promise to efficiently produce metal parts. However, LPBF incurs stochastic melt pool (MP) spattering, which would roughen workpiece in-process surface, thus weakening inter-layer bonding and causing…
Achieving desired mechanical properties in additive manufacturing requires many experiments and a well-defined design framework becomes crucial in reducing trials and conserving resources. Here, we propose a methodology embracing the…
Metal Laser Powder Bed Fusion (PBF-LB/M) is a leading additive manufacturing technique in which part quality and grain morphology are highly dependent on process parameters. Numerous studies of process variations, such as laser power, scan…
Laser powder bed fusion (LPBF) process can incur defects due to melt pool instabilities, spattering, temperature increase, and powder spread anomalies. Identifying defects through in-situ monitoring typically requires collecting, storing,…
Additive manufacturing processes are flexible and efficient technologies for producing complex geometries. However, ensuring reliability and repeatability is challenging due to the complex physics and various sources of uncertainty in the…
Variation in the local thermal history during the laser powder bed fusion (LPBF) process in additive manufacturing (AM) can cause microporosity defects. in-situ sensing has been proposed to monitor the AM process to minimize defects, but…
Laser Powder Bed Fusion (LPBF) additive manufacturing has revolutionized industries with its capability to create intricate and customized components. The LPBF process uses moving heat sources to melt and solidify metal powders. The fast…
Additive manufacturing (AM) is a rapidly evolving technology that has attracted applications across a wide range of fields due to its ability to fabricate complex geometries. However, one of the key challenges in AM is achieving consistent…
Laser powder bed fusion (LPBF) is an additive manufacturing technique that has gained popularity thanks to its ability to produce geometrically complex, fully dense metal parts. However, these parts are prone to internal defects and…
Defects in laser powder bed fusion (L-PBF) parts often result from the meso-scale dynamics of the molten alloy near the laser, known as the melt pool. For instance, the melt pool can directly contribute to the formation of undesirable…
Powder-based additive manufacturing has transformed the manufacturing industry over the last decade. In Laser Powder Bed Fusion, a specific part is built in an iterative manner in which two-dimensional cross-sections are formed on top of…
Laser Powder Bed Fusion (L-PBF) is a widely adopted additive manufacturing process for fabricating complex metallic parts layer by layer. Effective thermal management is essential to ensure part quality and structural integrity, as thermal…
This study demonstrates the significant effect of the recoil pressure and Marangoni convection in laser powder bed fusion (L-PBF) of 316L stainless steel. A three-dimensional high fidelity powder-scale model reveals how the strong dynamical…
Development and qualification of process parameters in laser powder bed fusion (LPBF) commonly involves many variables. At the outset of development, whether transferring known parameters to a new machine, or exploring a new material,…
Laser powder bed fusion (LPBF) is an additive manufacturing (AM) technology. To achieve high product quality, the powder is best spread as a uniform, dense layer. The challenge for LPBF manufacturers is to develop a spreading process that…
While multiple sensors are used for real-time monitoring in additive manufacturing, not all provide practical or reliable process insights. For example, high-speed X-ray imaging offers valuable spatial information about subsurface melt pool…
Numerical simulation of the laser powder bed fusion (LPBF) procedure for additive manufacturing (AM) is difficult due to the presence of multiple scales in both time and space, ranging from the part scale (order of millimeters/seconds) to…
With a growing demand for high-quality fabrication, the interest in real-time process and defect monitoring of laser powder bed fusion (LPBF) has increased, leading manufacturers to incorporate a variety of online sensing methods including…
Additive manufacturing by laser powder bed fusion (LPBF) offers material versatility, capability for complex geometries, and control of mechanical properties and microstructure. However, achieving high-quality output requires process…
Metal additive manufacturing (AM) by laser powder bed fusion (L-PBF) builds upon fundamentals established in the field of laser welding which include the influence of gas and plume dynamics on weld depth and quality. L-PBF demands a…