About this Abstract |
| Meeting |
2026 TMS Annual Meeting & Exhibition
|
| Symposium
|
In-Situ Monitoring and Control of Solidification & Deformation Processes in Metal Additive Manufacturing
|
| Presentation Title |
Revealing Optimal Melting Regimes for Defect Lean Thin-Walled Aluminium Laser Powder Bed Fusion Builds |
| Author(s) |
Rubén Lambert-Garcia, Samy Hocine, Maureen Fitzpatrick, Elena Ruckh, Kwan Kim, Anna C. M. Getley, Sebastian Marussi, Andy Farndell, Henry Greenhalgh, Michael Mallon, Marta Majkut, Alexander Rack, Nick Jones, Peter D. Lee, Chu Lun Alex Leung |
| On-Site Speaker (Planned) |
Rubén Lambert-Garcia |
| Abstract Scope |
Thin-wall additive manufacturing of AlSi10Mg, commonly employed in heat exchanger applications, faces significant challenges due to process instabilities during single-track printing. Through in situ synchrotron X-ray imaging, we systematically mapped the processing space and identified five distinct melting regimes, characterised by unique defect formation mechanisms. Our quantitative analysis of melt pool geometry, void nucleation, and melting efficiency revealed an optimal keyhole regime that achieves single tracks with minimal defects and 25% melting efficiency—representing an approximately 30% energy reduction compared to conventional conduction mode processing. Additionally, we observed a novel transitional phenomenon termed "keyhole flickering," characterised by rapid oscillation (~1 ms timescale) between keyhole and conduction melting modes. These findings establish a comprehensive process framework that advances our fundamental understanding of thin-wall aluminium additive manufacturing and provides valuable ground-truth data for process optimisation and the development of real-time process monitoring tools. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Aluminum, |