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<p>In laser powder bed fusion (LPBF) additive manufacturing, surface depressions caused by melt pool instability can induce defects throughout the layer-by-layer printing process. To address the limited understanding of interlayer defect transmission mechanisms, synchrotron X-ray in situ imaging was used to systematically investigate the dynamic evolution of surface depressions during multi-pass printing by adjusting interlayer process parameters. Experimental results show that insufficient energy input in the first layer leads to balling and fracture of melt tracks. When the energy input in the second layer is increased, local overheating at the gap between melt tracks from the previous layer causes surface depressions. Reducing the energy input in the third layer hinders melt backflow, enlarging the depression region. Further lowering the energy input in the final layer leads to the formation of internal unfused defects. This study reveals the dynamic correlation between surface depressions and interlayer defect evolution, offering critical experimental evidence and theoretical guidance for closed-loop interlayer process control in laser additive manufacturing.</p>

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In situ monitoring of surface depressions in metal laser additive manufacturing and its interlayer transfer mechanism

  • 期刊论文

  • 发表日期：

    2026年2月7日

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  • Jie Li,
  • Jie Wan,
  • Zi-jian Chen,
  • Jin-shan Li,
  • Jun Wang

摘要

In laser powder bed fusion (LPBF) additive manufacturing, surface depressions caused by melt pool instability can induce defects throughout the layer-by-layer printing process. To address the limited understanding of interlayer defect transmission mechanisms, synchrotron X-ray in situ imaging was used to systematically investigate the dynamic evolution of surface depressions during multi-pass printing by adjusting interlayer process parameters. Experimental results show that insufficient energy input in the first layer leads to balling and fracture of melt tracks. When the energy input in the second layer is increased, local overheating at the gap between melt tracks from the previous layer causes surface depressions. Reducing the energy input in the third layer hinders melt backflow, enlarging the depression region. Further lowering the energy input in the final layer leads to the formation of internal unfused defects. This study reveals the dynamic correlation between surface depressions and interlayer defect evolution, offering critical experimental evidence and theoretical guidance for closed-loop interlayer process control in laser additive manufacturing.