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Meeting 2027 TMS Annual Meeting & Exhibition
Symposium Advanced Real Time Imaging for Materials Science and Processing: 10th Anniversary
Presentation Title Gas Bubble and Keyhole Dynamics in Metal Additive Manufacturing with XFEL-Based Microscopy
Author(s) Lichao Fang
On-Site Speaker (Planned) Lichao Fang
Abstract Scope This study investigates the gas pore formation and keyhole dynamics during metal additive manufacturing for Aluminum alloys with X-ray Free-Electron Laser (XFEL) imaging. The processing atmosphere influences oxidation, gas–metal interactions, heat transfer, vapor-plume behavior, spatter transport, melt-pool stability, and pore formation. With the in situ and operando multiscale MHz X-ray radiography microscopy, we reveal bubble and keyhole dynamics under different environmental conditions. The pore populations are characterized by the X-ray computed tomography (CT). The keyhole and bubble migration are also predicted with high-fidelity multi-physics model to reveal keyhole dynamics and bubble translation in the melt pool. These findings provide a potential pathway for controlling pore formation and melt-pool instability in metal additive manufacturing.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Characterization, Modeling and Simulation

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