Issues $\rightarrow$ Volume 26, Issue 4 (2025)

The Influence of Physical Phenomena and Material Properties on the Quality of Parts during Selective Laser Melting

PODOLSKYI R.V.$^{1,2,3}$, ADZHAMSKYY S.V.$^{2,4}$, KONONENKO G.A.$^{2,5}$, and BADYUK S.I.$^{2,3}$

$^1$Iron and Steel Institute of Z.I. Nekrasov, N.A.S. of Ukraine, 1 Academician Starodubov Sq., UA-49107 Dnipro, Ukraine
$^2$LLC ‘Additive Laser Technologies of Ukraine’, 105 Nebesnoi Sotni Ave., UA-65104 Odesa, Ukraine
$^3$Institute of Applied Control Systems, N.A.S. of Ukraine, 40 Academician Glushkov Ave., UA-03187 Kyiv, Ukraine
$^4$Institute of Transport Systems and Technologies, N.A.S. of Ukraine, 5 Pisarzhevskoho St., UA-49000 Dnipro, Ukraine
$^5$National Technical University of Ukraine ‘Dniprovska Polytechnica’, 19 Dmytro Yavornytskyi Ave., UA-49005 Dnipro, Ukraine

Received / Final version: 27.03.2025 / 03.11.2025 Download PDF logo PDF

Abstract
The study is concerned with the analysis of key factors influencing the formation of defects, in particular porosity, in parts manufactured by selective laser melting (SLM). As SLM is increasingly used in relevant industries, achieving the high quality in the manufacturing process is of fundamental importance that can be ensured with a deep understanding of the processes occurring in it. The analysis of the interplay of laser radiation with metal powders (316L stainless steel, Ti6Al4V titanium alloy, AlSi10Mg aluminium alloy, Inconel 718 nickel superalloy) and physical processes in the melt pool, such as thermocapillary convection, heat transfer dynamics, metal-vapour pressure, and the spattering phenomenon, is performed. The dependence between the laser parameters (power, scanning speed, source and wavelength of radiation, backscattering coefficient, change in the angle of incident electrons), thermophysical properties of materials (thermal conductivity, surface tension, and coefficient of thermal expansion) and stability of track formation is established. As proven experimentally, the instability of the melt pool caused by temperature gradients and hydrodynamic effects is the main source of porosity. The dependence of the heat capacity on the temperature of steels and alloys used in SLM technology is obtained, and the influence of phase transformations on these patterns is shown. The features of mass transfer in the melt pool under the influence of the surface tension gradient and temperature gradient are considered. The analysis of the influence of molten-metal evaporation on powder erosion, melt splashing, creation of recoil pressure over the melt pool, and obstruction to the penetration of the laser beam is performed. A diagram of the transverse and longitudinal sections of the melt pool with the phenomena occurring in it is developed. Approaches to optimising the SLM process are proposed, namely, balancing energy parameters and using protective gases to minimise the number of defects and increase process stability. The results of the study emphasise the need for a comprehensive approach to managing the SLM process, taking into account both technological parameters and the specifics of materials. This opens up prospects for creating parts with minimal defects.

Keywords: selective laser melting, alloy, melt pool, single track, microstructure.

DOI: https://doi.org/10.15407/ufm.26.04.***

Citation: R.V. Podolskyi, S.V. Adzhamskyy, G.A. Kononenko, and S.I. Badyuk, The Influence of Physical Phenomena and Material Properties on the Quality of Parts during Selective Laser Melting, Progress in Physics of Metals, 26, No. 4: ***–*** (2025)

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