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<p>Laser energy assisted breakdown spectroscopy (LEABS) is a promising method for <i>in situ</i> monitoring in additive manufacturing for compositional verification of graded alloys and alloys with volatile species. In this study, <i>in situ</i> LEABS was used to monitor the elemental composition of AlSi10Mg deposits during single-track laser powder fusion on an AA1100 surface with variable processing laser power and in the presence of oxygen. <i>In situ</i> LEABS monitoring of the fused surface following the processing laser beam by about 3&#xa0;mm led to the observation of a ~ 63% decline in the intensity of the Si characteristic emission relative to that of Al when the processing laser power was increased from 400 to 800 W. Post-processing energy-dispersive X-ray spectroscopy analysis confirmed a decline in Si relative to Al, which contradicted the conventionally expected trend in relative elemental loss based on Si and Al boiling points. Equilibrium modeling of the melt pool vapor helped to link the loss of Si at higher processing powers to the presence of oxygen in the processing chamber. Oxygen was shown to strongly affect relative loss of the AlSi10Mg alloy elements through the formation of volatile oxides. The spectroscopically observed Si depletion was supported with a comparison of atomic and oxidized species in the modelled vapor compositions. This effect was additionally confirmed with laser fusion of AlSi10Mg powder on a Cu surface, where an inverse relationship between oxygen concentration and silicon concentration was established. Results highlight the feasibility of LEABS as a method for real-time, <i>in situ</i> monitoring of alloy composition during powder fusion.</p>

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In situ spectroscopic composition monitoring of AlSi10Mg powder fusion

  • 期刊论文

  • 发表日期：

    2026年8月4日

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  • Jacob T. Spencer,
  • Brian M. Squires,
  • Narendra B. Dahotre,
  • Andrey A. Voevodin

摘要

Laser energy assisted breakdown spectroscopy (LEABS) is a promising method for in situ monitoring in additive manufacturing for compositional verification of graded alloys and alloys with volatile species. In this study, in situ LEABS was used to monitor the elemental composition of AlSi10Mg deposits during single-track laser powder fusion on an AA1100 surface with variable processing laser power and in the presence of oxygen. In situ LEABS monitoring of the fused surface following the processing laser beam by about 3 mm led to the observation of a ~ 63% decline in the intensity of the Si characteristic emission relative to that of Al when the processing laser power was increased from 400 to 800 W. Post-processing energy-dispersive X-ray spectroscopy analysis confirmed a decline in Si relative to Al, which contradicted the conventionally expected trend in relative elemental loss based on Si and Al boiling points. Equilibrium modeling of the melt pool vapor helped to link the loss of Si at higher processing powers to the presence of oxygen in the processing chamber. Oxygen was shown to strongly affect relative loss of the AlSi10Mg alloy elements through the formation of volatile oxides. The spectroscopically observed Si depletion was supported with a comparison of atomic and oxidized species in the modelled vapor compositions. This effect was additionally confirmed with laser fusion of AlSi10Mg powder on a Cu surface, where an inverse relationship between oxygen concentration and silicon concentration was established. Results highlight the feasibility of LEABS as a method for real-time, in situ monitoring of alloy composition during powder fusion.