A Testbed for Investigation of Selective Laser Melting at Elevated Atmospheric Pressure

TL;DR

This paper introduces a high-pressure laser melting testbed for studying the effects of elevated atmospheric pressure on metal additive manufacturing processes, enabling detailed analysis of melt pool dynamics and material behavior.

Contribution

The paper presents the design and validation of a novel high-pressure laser melting system that allows controlled experiments on melt pool behavior at pressures up to 300 psig.

Findings

Pressure significantly affects melt pool aspect ratio.

System validation shows reliable control of laser parameters and gas environment.

Preliminary results indicate potential for processing challenging materials.

Abstract

Metal additive manufacturing (AM) by laser powder bed fusion (L-PBF) builds upon fundamentals established in the field of laser welding which include the influence of gas and plume dynamics on weld depth and quality. L-PBF demands a thorough investigation of the complex thermophysical phenomena that occur where the laser interacts with the metal powder bed. In particular, melt pool turbulence and evaporation are influenced by the ambient gas chemistry and pressure. This paper presents the design and validation of high pressure laser melting (HPLM) testbed; this accommodates bare metal plate samples as well as manually-coated single powder layers, and operates at up to 300 psig. The open architecture of this testbed allows for full control of all relevant laser parameters in addition to ambient gas pressure and gas flow over the build area. Representative melt tracks and rasters on bare plate and powder are examined in order to validate system performance, and preliminary analysis concludes that pressure has a significant impact on melt pool aspect ratio. The HPLM system thus enables careful study pressure effects on processing of common L-PBF materials, and can be applied in the future to materials that are challenging to process under ambient pressure, such as those with high vapor pressures.