Pore evolution mechanisms during directed energy deposition additive manufacturing
© 2024. The Author(s)..
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.
| Medienart: |
E-Artikel |
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| Erscheinungsjahr: |
2024 |
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| Erschienen: |
2024 |
| Enthalten in: |
Zur Gesamtaufnahme - volume:15 |
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| Enthalten in: |
Nature communications - 15(2024), 1 vom: 24. Feb., Seite 1715 |
| Sprache: |
Englisch |
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| Beteiligte Personen: |
Zhang, Kai [VerfasserIn] |
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| Links: |
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| Anmerkungen: |
Date Revised 27.02.2024 published: Electronic Citation Status PubMed-not-MEDLINE |
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| doi: |
10.1038/s41467-024-45913-9 |
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| funding: |
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| Förderinstitution / Projekttitel: |
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| 520 | |a © 2024. The Author(s). | ||
| 520 | |a 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 | ||
| 650 | 4 | |a Journal Article | |
| 700 | 1 | |a Chen, Yunhui |e verfasserin |4 aut | |
| 700 | 1 | |a Marussi, Sebastian |e verfasserin |4 aut | |
| 700 | 1 | |a Fan, Xianqiang |e verfasserin |4 aut | |
| 700 | 1 | |a Fitzpatrick, Maureen |e verfasserin |4 aut | |
| 700 | 1 | |a Bhagavath, Shishira |e verfasserin |4 aut | |
| 700 | 1 | |a Majkut, Marta |e verfasserin |4 aut | |
| 700 | 1 | |a Lukic, Bratislav |e verfasserin |4 aut | |
| 700 | 1 | |a Jakata, Kudakwashe |e verfasserin |4 aut | |
| 700 | 1 | |a Rack, Alexander |e verfasserin |4 aut | |
| 700 | 1 | |a Jones, Martyn A |e verfasserin |4 aut | |
| 700 | 1 | |a Shinjo, Junji |e verfasserin |4 aut | |
| 700 | 1 | |a Panwisawas, Chinnapat |e verfasserin |4 aut | |
| 700 | 1 | |a Leung, Chu Lun Alex |e verfasserin |4 aut | |
| 700 | 1 | |a Lee, Peter D |e verfasserin |4 aut | |
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