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About this Abstract
Meeting 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Symposium 2026 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2026)
Presentation Title Spattering in Laser Powder Bed Fusion: Physics-based Simulations, Formation Mechanisms, and Reduction Strategies
Author(s) Fangzhou Li, Haoran Shi, Wenda Tan
On-Site Speaker (Planned) Haoran Shi
Abstract Scope Powder spattering in laser powder bed fusion (LPBF) processes leads to multiple quality-critical defects in the additively manufactured parts, and effective strategies for spatter reduction are needed for process optimization. In this work, a multi-physics model that incorporates computational fluid dynamics and computational powder dynamics is developed to simulate the keyhole evolution, vapor plume dynamics, and the powder spattering during LPBF. The model is validated against in-situ observation of the powder motion in LPBF, and leveraged to quantitatively understand the formation mechanisms of spatters. The spatial distributions of the spattering particles were found from the simulations, which offer a new perspective to quantify the spattering behavior of the particle. Inspired by this new perspective, different beam shapes have been selected to reduce spatters in LPBF, and their effectiveness has been investigated.
Proceedings Inclusion? Undecided

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