Open AccessUnderstanding the Rayleigh instability in humping phenomenon during laser powder bed fusion process
Author(s) -
Wenxuan Zhang,
Wenyuan Hou,
Luc Deike,
Craig B. Arnold
Publication year - 2022
Publication title -
international journal of extreme manufacturing
Language(s) - English
Resource type - Journals
eISSN - 2631-8644
pISSN - 2631-7990
DOI - 10.1088/2631-7990/ac466d
Subject(s) - instability , fusion , inertial confinement fusion , materials science , laser , rayleigh scattering , mechanics , rayleigh–taylor instability , jump , dwell time , optics , physics , philosophy , linguistics , medicine , clinical psychology , quantum mechanics
The periodic undulation of a molten track’s height profile in laser-based powder bed fusion of metals (PBF-LB/M) is a commonly observed phenomena that can cause defects and building failure during the manufacturing process. However a quantitative analysis of such instabilities has not been fully established and so here we used Rayleigh–Plateau theory to determine the stability of a single molten track in PBF-LB/M and tested it with various processing conditions by changing laser power and beam shape. The analysis discovered that normalized enthalpy, which relates to energy input density, determines whether a molten track is initially unstable and if so, the growth rate for the instability. Additionally, whether the growth rate ultimately yields significant undulation depends on the melt duration, estimated by dwell time in our experiment.