Operando tomographic microscopy during laser-based powder bed fusion of alumina

Laser-based Powder Bed Fusion (LPBF) of oxide ceramics enables fabrication of objects with complex three-dimensional shapes. However, mechanical properties of dense LPBF-manufactured ceramics are poor due to large amount of structural defects. Here, we perform the operando tomographic microscopy during LPBF of a magnetite-modified alumina to gain a deeper understanding of the underlying mechanisms. The effect of the laser energy density on the surface roughness, powder denudation zone and porosity formation mechanisms are investigated. Increasing laser power results in significant increase of the melt pool width, but not its depth and no melt pool depression is observed. Forces due to the recoil pressure are not seen to significantly influence the melt pool dynamics. Increasing power allows to avoid fusion porosity but enhances formation of spherical porosity that is formed by either reaching boiling point of liquid alumina, or by introducing gas bubbles by injection of hollow powder particles into the liquid. Understanding the effects of changing process parameters during additive manufacturing is vital for building high-quality parts. Here, operando tomographic microscopy during laser-based processing of alumina reveals detailed insight into process dynamics, including melt pool behavior and defect formation.

Automated summary

Laser-based Powder Bed Fusion (LPBF) of oxide ceramics allows for fabrication of complex three-dimensional objects, but the mechanical properties of dense LPBF-manufactured ceramics are poor due to structural defects. In this study, operando tomographic microscopy is used to investigate the effects of laser energy density on surface roughness, powder denudation zone, and porosity formation mechanisms. The findings show that increasing laser power results in wider melt pools without affecting their depth, and that increasing power can both eliminate fusion porosity and enhance the formation of spherical porosity.