A Review of Spatter in Laser Powder Bed Fusion Additive Manufacturing: In Situ Detection, Generation, Effects, and Countermeasures

Abstract

Spatter is an inherent, unpreventable, and undesired phenomenon in laser powder bed fusion (L-PBF) additive manufacturing. Spatter behavior has an intrinsic correlation with the forming quality in L-PBF because it leads to metallurgical defects and the degradation of mechanical properties. This impact becomes more severe in the fabrication of large-sized parts during the multi-laser L-PBF process. Therefore, investigations of spatter generation and countermeasures have become more urgent. Although much research has provided insights into the melt pool, microstructure, and mechanical property, reviews of spatter in L-PBF are still limited. This work reviews the literature on the in situ detection, generation, effects, and countermeasures of spatter in L-PBF. It is expected to pave the way towards a novel generation of highly efficient and intelligent L-PBF systems.

Editorial for the Special Issue on Laser Additive Manufacturing: Design, Processes, Materials and Applications

“…Li et al [16] reviewed the literature on the in situ detection, generation, effects and countermeasures of spatter in L-PBF, which has an intrinsic correlation with the forming quality. Although many researchers have provided insights into the melt pool, microstructure and mechanical property, reviews of spatter in L-PBF are still limited.…”

Alloy design for laser powder bed fusion additive manufacturing: a critical review

“…The purpose of this review work is to provide guidance and new insights for designing novel alloys specifically tailored for L-PBF. [44]. Reproduced from [44].…”

High Reflectivity and Thermal Conductivity Ag–Cu Multi-Material Structures Fabricated via Laser Powder Bed Fusion: Formation Mechanisms, Interfacial Characteristics, and Molten Pool Behavior

“…[ 21 ] can be achieved to meet the growing demands of the aerospace, biomedical, automotive, and jewelry industries, among others [ 22 ]. Laser powder bed fusion (LPBF) is a common metal additive manufacturing process [ 23 , 24 ] that has the advantages of precision manufacturing and multi-scale precision control [ 25 ]. In the LPBF process, the combination of laser rapid solidification and high thermal conductivity metal contributes to promote grain refinement [ 17 ], which provides the possibility to improve the comprehensive performance of HETCMs [ 1 ].…”