| Abstract Scope |
Quality assurance in Laser Powder Bed Fusion (LPBF) remains challenging due to the interdependent nature of defect formation across the additive manufacturing process chain. Critical defects such as lack of fusion, porosity, cracking, embrittlement, distortion, and mechanical property drift arise from interactions among powder characteristics, process stability, thermal history, chamber conditions, and post-processing operations. While conventional Process Failure Mode and Effects Analysis (PFMEA) provides structured process risk evaluation, its process-step-oriented structure limits systematic tracing of defect origins and propagation pathways.
This work proposes a defect-oriented risk and monitoring framework for LPBF quality assurance that combines defect-driven backward mapping and process-driven forward mapping. The framework links process conditions, defect formation mechanisms, metallurgical consequences, monitoring opportunities, and final quality effects within an interconnected defect–process structure. The proposed approach supports defect-origin identification, monitoring prioritization, and risk-informed quality assurance strategies for demanding LPBF production environments. |