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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Additive Manufacturing Modeling, Simulation and Artificial Intelligence
Presentation Title Spatters in Laser Powder Bed Fusion: Physics-based Simulations, Formation Mechanisms, and Reduction Strategies
Author(s) Wenda Tan
On-Site Speaker (Planned) Wenda Tan
Abstract Scope Powder spattering in laser powder bed fusion (LPBF) process leads to multiple quality-critical defects in additive manufacturing (AM) parts, so effective strategies for spatter reduction are demanded for the AM process optimization and product qualification. In this work, a multi-physics model that incorporates computational fluid dynamics and computational powder dynamics is developed to simulate the dynamic phenomena in the depression zone, melt pool, vapor plume, and powder bed during LPBF. The model is validated against in-situ observation of the powder motion during printing, and then leveraged to quantitatively understand the formation mechanisms of spatters. The spatial distributions of the spattering particles are found from the simulations, which offers a new perspective to quantify the spattering behavior of the particle. Inspired by this new perspective, different beam shapes have been selected for LPBF to reduce spatters, and their effectiveness has been discussed.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Modeling and Simulation,

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