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Meeting 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Symposium 2025 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2025)
Presentation Title Powder Particle Impact Behavior in Laser, Powder-Blown Directed Energy
Author(s) Samantha Webster, Sasha Menchaca, Jihoon Jeong, Shuheng Liao, Jian Cao, Samuel Clark, Kamel Fezzaa
On-Site Speaker (Planned) Samantha Webster
Abstract Scope Process defects limit the use of additive manufacturing (AM) components due to shorter fatigue life and lower strength. Conditions under which these defects form are readily investigated through in situ, high-speed X-ray imaging. In this study, highspeed X-ray imaging of powder particle impact behavior in DED for both Ti-6Al-4V and SS316 was performed at the Advanced Photon Source. It was found that pore formation can be driven by the collapse of the vapor cavity formed behind a solid powder particle as it enters the liquid melt pool. This is a unique mechanism to powder-blown processes and demonstrates the importance of powder particle contact angle, size, and velocity. An analytical model for the critical velocity will be presented to connect the experimental findings to guidelines for powder flow. By understanding powder-melt pool interactions, thresholds for powder flow can be established, enabling higher quality materials to be manufactured through DED.
Proceedings Inclusion? Planned: Post-meeting proceedings

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Thermal Exposure Optimization for Enhanced Interlayer Strength in FFF-Printed ABS: A DOE and Microstructural Investigation
Thermal History Prediction of More Complex Geometries for DED Based on SciML
Thermal Monitoring in AC Selective Laser Flash Sintering of Ceramics Using a Mid-Wave Infrared Photodiode
Toolpath Planning for Multi-Nozzle Concurrent Molten Metal Jetting Process
Top Layer Quality Assurance of Complex Geometries Based on Region of Interest in Additive Manufacturing
Topology and Orientation Optimized-Inspired Toolpath Planning for Continuous Fiber Material Extrusion
Toward Real-Time Finite Element Analysis-Informed Feedback Control of Wire-Arc Directed Energy Deposition via Robot Operating System 2 In-Situ Monitoring System
Towards Parametric Design for Additive Manufacturing of Coral Structures Using a Digital Twin Approach
Towards Scalable and Energy-Efficient Extrusion Additive Manufacturing of Thermoplastic Polymer Composites
Towards the Production of a 3D Part in Selective Laser Additive Manufacturing Acousto-Optic Light Engine (SLAM – ALE)
Train Small, Predict Big: Scalable Thermal Surrogate Modeling for LPBF Using MODAL
Transfer Learning for Process–Microstructure–Property Mapping in Micro Selective Laser Sintering
Transient Liquid Phase Surface Smoothing
Tribo-Mechanical and Corrosion Characteristics of SS316L-IN625 Alloys of Varying Compositions Fabricated by Twin Wire WAAM-TIG
Two-Component Thermoset Polymer Formwork for Concrete Casting
Uncovering Process-Structure Relationships in Directed Energy Deposition of Nickel-Based Alloys on Low-Alloy Steel with Post-Deposition Heat Treatment
Understanding Hardening Behavior Induced by Interlayer Shot Peening in Laser Powder Bed Fusion of 316L Stainless Steel
Understanding Multi-Line Printing and the Effects of Controlled Prewetting on Binder Jetting Print Cohesion
Understanding Sources of Spatial Density Variation in Green Parts Produced by Binder Jetting
Understanding the Effect of Heat Treatment on Mechanical Properties of Additive Manufactured 1.2709 Grade Maraging Steel
Understanding the Feasibility of Using NiTi55 Interlayer for Ti6Al4V-18Ni Maraging Steel Multi-Metal Deposition in L-PBF
Use of In-Situ Thermography to Study Scan Strategy for Laser Foil Printing of Metallic Glass
Using Acoustic Signals For Torch-to-Bead Distance Estimation and Closed-Loop Control in Wire Arc Additive Manufacturing
Using Coaxial Melt Pool Images to Construct In-Process 3D Volume Model in Powder Bed Fusion Additive Manufacturing
Using Machine Learning-Based Process Map to Guide Evaluation of Inconel 625 Mechanical Properties in Laser Foil Printing
Vat Photopolymerization of Na3V2(PO4)3-Based Electrodes for Sodium-Ion Batteries
Vat Photopolymerization of Ultra-Soft Polymer Foams
Volumetric Medical Models: Direct Imaging to Functional 3D Prints
Wire Arc Additive Manufacturing Benefits and Challenges: A Survey
Wire Arc Additive Manufacturing Development for Aluminum 6061 RAM
Wire Arc Additive Manufacturing of a Large Scale, High Aspect Ratio, Multi-Material Part
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