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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…
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…
In our study, molecular dynamics (MD) simulations of laser powder bed fusion (LPBF) have been conducted on equimolar FeNiCr medium entropy alloy (MEA) powders. With the development of newer LPBF technologies capable of printing at 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…
Foundation models are at the forefront of an increasing number of critical applications. In regards to technologies such as additive manufacturing (AM), these models have the potential to dramatically accelerate process optimization and, in…
Qualification of high-performance metal components produced by laser powder bed fusion (LPBF) must identify process-induced porous defects that reduce ductility and nucleate fatigue cracking. Detecting such defects via optical monitoring of…
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,…
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…
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…
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…
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…
Open-loop control of laser powder bed fusion (LPBF) additive manufacturing (AM) has enabled the production of complex, high-criticality parts for various industries. This method relies on static parameter sets from extensive experimentation…
LPBF of Al alloys is associated with numerous challenges when compared to other commonly used alloys due to their higher reflectivity and thermal conductivity. In this work, processing diagrams, temperature prediction models, XCT, and…
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,…
In this study, the effects of surface roughness and pore characteristics on fatigue lives of laser powder bed fusion (LPBF) Ti-6Al-4V parts were investigated. The 197 fatigue bars were printed using the same laser power but with varied…
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…
Laser powder bed fusion (LPBF) has shown promise for wide range of applications due to its ability to fabricate freeform geometries and generate a controlled microstructure. However, components generated by LPBF still possess sub-optimal…
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…
Limited process control can cause metallurgical defect formation and inhomogeneous relative density in laser powder bed fusion manufactured parts. In this study, cylindrical 15-5 PH stainless steel specimens are investigated by computer…
The mitigation of material defects from additive manufacturing (AM) processes is critical to reliability in their fabricated parts and is enabled by modeling the complex relations between available build monitoring signals and final…