IDEAS home Printed from https://ideas.repec.org/a/nat/natcom/v15y2024i1d10.1038_s41467-024-45913-9.html
   My bibliography  Save this article

Pore evolution mechanisms during directed energy deposition additive manufacturing

Author

Listed:
  • Kai Zhang

    (University College London
    Research Complex at Harwell, Harwell Campus)

  • Yunhui Chen

    (University College London
    Research Complex at Harwell, Harwell Campus
    ESRF—The European Synchrotron
    RMIT University)

  • Sebastian Marussi

    (University College London
    Research Complex at Harwell, Harwell Campus)

  • Xianqiang Fan

    (University College London
    Research Complex at Harwell, Harwell Campus)

  • Maureen Fitzpatrick

    (University College London
    ESRF—The European Synchrotron)

  • Shishira Bhagavath

    (University College London
    Research Complex at Harwell, Harwell Campus)

  • Marta Majkut

    (ESRF—The European Synchrotron)

  • Bratislav Lukic

    (ESRF—The European Synchrotron)

  • Kudakwashe Jakata

    (ESRF—The European Synchrotron
    Harwell Campus)

  • Alexander Rack

    (ESRF—The European Synchrotron)

  • Martyn A. Jones

    (Rolls-Royce plc)

  • Junji Shinjo

    (Shimane University)

  • Chinnapat Panwisawas

    (Queen Mary University of London)

  • Chu Lun Alex Leung

    (University College London
    Research Complex at Harwell, Harwell Campus)

  • Peter D. Lee

    (University College London
    Research Complex at Harwell, Harwell Campus)

Abstract

Porosity in directed energy deposition (DED) deteriorates mechanical performances of components, limiting safety-critical applications. However, how pores arise and evolve in DED remains unclear. Here, we reveal pore evolution mechanisms during DED using in situ X-ray imaging and multi-physics modelling. We quantify five mechanisms contributing to pore formation, migration, pushing, growth, removal and entrapment: (i) bubbles from gas atomised powder enter the melt pool, and then migrate circularly or laterally; (ii) small bubbles can escape from the pool surface, or coalesce into larger bubbles, or be entrapped by solidification fronts; (iii) larger coalesced bubbles can remain in the pool for long periods, pushed by the solid/liquid interface; (iv) Marangoni surface shear flow overcomes buoyancy, keeping larger bubbles from popping out; and (v) once large bubbles reach critical sizes they escape from the pool surface or are trapped in DED tracks. These mechanisms can guide the development of pore minimisation strategies.

Suggested Citation

  • Kai Zhang & Yunhui Chen & Sebastian Marussi & Xianqiang Fan & Maureen Fitzpatrick & Shishira Bhagavath & Marta Majkut & Bratislav Lukic & Kudakwashe Jakata & Alexander Rack & Martyn A. Jones & Junji S, 2024. "Pore evolution mechanisms during directed energy deposition additive manufacturing," Nature Communications, Nature, vol. 15(1), pages 1-14, December.
    • Handle: RePEc:nat:natcom:v:15:y:2024:i:1:d:10.1038_s41467-024-45913-9
    DOI: 10.1038/s41467-024-45913-9
    as

    Download full text from publisher

    File URL: https://www.nature.com/articles/s41467-024-45913-9
    File Function: Abstract
    Download Restriction: no
    File URL: https://libkey.io/10.1038/s41467-024-45913-9?utm_source=ideas
    LibKey link: if access is restricted and if your library uses this service, LibKey will redirect you to where you can use your library subscription to access this item
    ---><---

    References listed on IDEAS

    as
    1. Minglei Qu & Qilin Guo & Luis I. Escano & Ali Nabaa & S. Mohammad H. Hojjatzadeh & Zachary A. Young & Lianyi Chen, 2022. "Publisher Correction: Controlling process instability for defect lean metal additive manufacturing," Nature Communications, Nature, vol. 13(1), pages 1-1, December.
    2. Zhongji Sun & Yan Ma & Dirk Ponge & Stefan Zaefferer & Eric A. Jägle & Baptiste Gault & Anthony D. Rollett & Dierk Raabe, 2022. "Thermodynamics-guided alloy and process design for additive manufacturing," Nature Communications, Nature, vol. 13(1), pages 1-12, December.
    3. Aiden A. Martin & Nicholas P. Calta & Saad A. Khairallah & Jenny Wang & Phillip J. Depond & Anthony Y. Fong & Vivek Thampy & Gabe M. Guss & Andrew M. Kiss & Kevin H. Stone & Christopher J. Tassone & J, 2019. "Dynamics of pore formation during laser powder bed fusion additive manufacturing," Nature Communications, Nature, vol. 10(1), pages 1-10, December.
    4. Minglei Qu & Qilin Guo & Luis I. Escano & Ali Nabaa & S. Mohammad H. Hojjatzadeh & Zachary A. Young & Lianyi Chen, 2022. "Controlling process instability for defect lean metal additive manufacturing," Nature Communications, Nature, vol. 13(1), pages 1-8, December.
    5. Zhengtao Gan & Orion L. Kafka & Niranjan Parab & Cang Zhao & Lichao Fang & Olle Heinonen & Tao Sun & Wing Kam Liu, 2021. "Universal scaling laws of keyhole stability and porosity in 3D printing of metals," Nature Communications, Nature, vol. 12(1), pages 1-8, December.
    6. Yuze Huang & Tristan G. Fleming & Samuel J. Clark & Sebastian Marussi & Kamel Fezzaa & Jeyan Thiyagalingam & Chu Lun Alex Leung & Peter D. Lee, 2022. "Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing," Nature Communications, Nature, vol. 13(1), pages 1-11, December.
    Full references (including those not matched with items on IDEAS)

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Dongsheng Zhang & Wei Liu & Yuxiao Li & Darui Sun & Yu Wu & Shengnian Luo & Sen Chen & Ye Tao & Bingbing Zhang, 2023. "In situ observation of crystal rotation in Ni-based superalloy during additive manufacturing process," Nature Communications, Nature, vol. 14(1), pages 1-11, December.
    2. Shivam Gupta & Sachin Modgil & Piera Centobelli & Roberto Cerchione & Serena Strazzullo, 2022. "Additive Manufacturing and Green Information Systems as Technological Capabilities for Firm Performance," Global Journal of Flexible Systems Management, Springer;Global Institute of Flexible Systems Management, vol. 23(4), pages 515-534, December.
    3. David Guirguis & Conrad Tucker & Jack Beuth, 2024. "Accelerating process development for 3D printing of new metal alloys," Nature Communications, Nature, vol. 15(1), pages 1-12, December.
    4. Neng Ren & Jun Li & Ruiyao Zhang & Chinnapat Panwisawas & Mingxu Xia & Hongbiao Dong & Jianguo Li, 2023. "Solute trapping and non-equilibrium microstructure during rapid solidification of additive manufacturing," Nature Communications, Nature, vol. 14(1), pages 1-13, December.
    5. Yuze Huang & Tristan G. Fleming & Samuel J. Clark & Sebastian Marussi & Kamel Fezzaa & Jeyan Thiyagalingam & Chu Lun Alex Leung & Peter D. Lee, 2022. "Keyhole fluctuation and pore formation mechanisms during laser powder bed fusion additive manufacturing," Nature Communications, Nature, vol. 13(1), pages 1-11, December.
    6. Milad Hamidi Nasab & Giulio Masinelli & Charlotte Formanoir & Lucas Schlenger & Steven Petegem & Reza Esmaeilzadeh & Kilian Wasmer & Ashish Ganvir & Antti Salminen & Florian Aymanns & Federica Marone , 2023. "Harmonizing sound and light: X-ray imaging unveils acoustic signatures of stochastic inter-regime instabilities during laser melting," Nature Communications, Nature, vol. 14(1), pages 1-14, December.
    7. Deyuan Ma & Ping Jiang & Leshi Shu & Zhaoliang Gong & Yilin Wang & Shaoning Geng, 2024. "Online porosity prediction in laser welding of aluminum alloys based on a multi-fidelity deep learning framework," Journal of Intelligent Manufacturing, Springer, vol. 35(1), pages 55-73, January.
    8. Xiaoyu Xie & Arash Samaei & Jiachen Guo & Wing Kam Liu & Zhengtao Gan, 2022. "Data-driven discovery of dimensionless numbers and governing laws from scarce measurements," Nature Communications, Nature, vol. 13(1), pages 1-11, December.
    9. Paromita Nath & Sankaran Mahadevan, 2023. "Probabilistic predictive control of porosity in laser powder bed fusion," Journal of Intelligent Manufacturing, Springer, vol. 34(3), pages 1085-1103, March.

    More about this item

    Statistics

    Access and download statistics

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:nat:natcom:v:15:y:2024:i:1:d:10.1038_s41467-024-45913-9. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: Sonal Shukla or Springer Nature Abstracting and Indexing (email available below). General contact details of provider: http://www.nature.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.