Laser-matter interactions in additive manufacturing of SS316L and 13-93 bioactive glass revealed by in situ X-ray imaging

Chu Lun Alex Leung, Sebastian Marussi, Michael Towrie, Jesus del Val Garcia, Robert C. Atwood, Andrew J. Bodey, Julian R. Jones, Philip J. Withers, Peter D.Lee

Laser-matter interactions in laser additive manufacturing (LAM) occur on short time scales (10-6 – 10-3 s) and have traditionally proven difficult to characterise. We investigate these interactions during LAM of stainless steel (SS316 L) and 13-93 bioactive glass powders using a custom built LAM process replicator (LAMPR) with in situ and operando synchrotron X-ray radiography. This reveals a range of melt track solidification phenomena as well as spatter and porosity formation. We hypothesise that the SS316 L powder absorbs the laser energy at its surface while the trace elements in the 13-93 bioactive glass powder absorb the laser energy by radiation conduction. Our results show that a low viscosity melt, e.g. 8 mPa s for SS316 L, tends to generate spatter with a diameter up to 250 µm and an average spatter velocity of 0.26 m s-1 and form a melt track by molten pool wetting. In contrast, a high viscosity melt, e.g. 2 Pa s for 13-93 bioactive glass, inhibits spatter formation by damping the Marangoni convection, forming a melt track via viscous flow. The viscous flow in 13-93 bioactive glass resists pore transport; combined with the reboil effect, this promotes pore growth during LAM, resulting in a pore size up to 500 times larger than that exhibited in the SS316 L sample.

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For the XCT dataset, we quantified the pore size distribution of both melt tracks in 3D using Avizo 9.1 (Thermo Fisher Scientific, US) and the method described in the literature [13,56]. We discarded any segmented objects with a volume fewer than five voxels (equivalent to a diameter of 6.75 µm) to minimize quantification errors induced by image noise.

For Research Use Only. Not for use in diagnostic procedures.

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