About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Advanced Real Time Imaging for Materials Science and Processing: 10th Anniversary
|
| Presentation Title |
Operando X-ray Imaging of Porosity Formation During Wire-Laser Directed Energy Deposition |
| Author(s) |
Xingyang Li, Alan L. Kastengren, Samuel J. Clark, Kyle Mumm, Dukyong Kim, Sihang Feng, Zhiyuan Li, Tao Sun |
| On-Site Speaker (Planned) |
Xingyang Li |
| Abstract Scope |
Wire-laser directed energy deposition (wire-laser DED) is known for producing high-density parts with low porosity, owing to the use of continuous wire feedstock and the reduced likelihood of powder-related defects. However, pores other than lack-of-fusion defects are still observed, and the formation mechanisms of these pores remain unclear. In this work, high-speed operando synchrotron X-ray imaging was used to directly observe pore generation during wire-laser DED. A pore-formation mechanism associated with the wire-fed geometry was identified, in which partial melting of the incoming wire and surface-tension-driven melt behavior induced bubble formation in the melt pool. Bubble motion, coalescence, and entrapment during solidification were further analyzed. Complementary multiphysics simulations were conducted to interpret the observed bubble formation and melt-pool dynamics. By correlating melt-pool behavior with final pore distribution, this study identifies process conditions that promote pore formation and provides guidance for reducing porosity, improving process stability, and enhancing part quality. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, Modeling and Simulation, Other |