Abstract
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 process. Particularly, the stochastic formation of large spatters leads to unpredictable defects in the as-printed parts. Here we report the elimination of large spatters through controlling laser-powder bed interaction instabilities by using nanoparticles. The elimination of large spatters results in 3D printing of defect lean sample with good consistency and enhanced properties. We reveal that two mechanisms work synergistically to eliminate all types of large spatters: (1) nanoparticle-enabled control of molten pool fluctuation eliminates the liquid breakup induced large spatters; (2) nanoparticle-enabled control of the liquid droplet coalescence eliminates liquid droplet colliding induced large spatters. The nanoparticle-enabled simultaneous stabilization of molten pool fluctuation and prevention of liquid droplet coalescence discovered here provide a potential way to achieve defect lean metal additive manufacturing.
| Original language | English |
|---|---|
| Article number | 1079 |
| Journal | Nature Communications |
| Volume | 13 |
| Issue number | 1 |
| DOIs | |
| State | Published - Dec 2022 |
| Externally published | Yes |
Funding
The authors would like to thank beamline scientists Drs. Kamel Fezzaa, Tao Sun and Chihpin Andrew Chuang at the APS for their help on the beamline experiments. The authors acknowledge use of facilities and instrumentation at the UW-Madison Wisconsin Centers for Nanoscale Technology (wcnt.wisc.edu) partially supported by the NSF through the University of Wisconsin Materials Research Science and Engineering Center (DMR-1720415). This work is supported by National Science Foundation (Award No. 2002840, L.C.) and University of Wisconsin-Madison Startup Fund (L.C.). This research used resources of the Advanced Photon Source, a U.S. Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under contract DE-AC02-06CH11357. The authors would like to thank beamline scientists Drs. Kamel Fezzaa, Tao Sun and Chihpin Andrew Chuang at the APS for their help on the beamline experiments. The authors acknowledge use of facilities and instrumentation at the UW-Madison Wisconsin Centers for Nanoscale Technology (wcnt.wisc.edu) partially supported by the NSF through the University of Wisconsin Materials Research Science and Engineering Center (DMR-1720415). This work is supported by National Science Foundation (Award No. 2002840, L.C.) and University of Wisconsin-Madison Startup Fund (L.C.). This research used resources of the Advanced Photon Source, a U.S. Department of Energy (DOE) Office of Science User Facility operated for the DOE Office of Science by Argonne National Laboratory under contract DE-AC02-06CH11357.
| Funders | Funder number |
|---|---|
| University of Wisconsin Materials Research Science and Engineering Center | DMR-1720415 |
| National Science Foundation | 2002840 |
| U.S. Department of Energy | |
| Office of Science | |
| Argonne National Laboratory | DE-AC02-06CH11357 |
| University of Wisconsin-Madison | |
| College of Engineering, University of Wisconsin-Madison | |
| American Pain Society |
