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Metal additive manufacturing (AM) by laser powder bed fusion (L-PBF) buildsupon fundamentals established in the field of laser welding which include theinfluence of gas and plume dynamics on weld depth and quality. L-PBF demands athorough investigation of the complex thermophysical phenomena that occur wherethe laser interacts with the metal powder bed. In particular, melt poolturbulence and evaporation are influenced by the ambient gas chemistry andpressure. This paper presents the design and validation of high pressure lasermelting (HPLM) testbed; this accommodates bare metal plate samples as well asmanually-coated single powder layers, and operates at up to 300 psig. The openarchitecture of this testbed allows for full control of all relevant laserparameters in addition to ambient gas pressure and gas flow over the buildarea. Representative melt tracks and rasters on bare plate and powder areexamined in order to validate system performance, and preliminary analysisconcludes that pressure has a significant impact on melt pool aspect ratio. TheHPLM system thus enables careful study pressure effects on processing of commonL-PBF materials, and can be applied in the future to materials that arechallenging to process under ambient pressure, such as those with high vaporpressures.

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