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Zhun Su, Wenquan Lu, Zongye Ding, Liang Zhao, Fan Yang, Jianguo Li, and Qiaodan Hu, In-situ observation on bubble evolution during laser powder bed fusion of oxide ceramic, Int. J. Miner. Metall. Mater., 32(2025), No. 6, pp.1451-1460. https://doi.org/10.1007/s12613-025-3170-2
Zhun Su, Wenquan Lu, Zongye Ding, Liang Zhao, Fan Yang, Jianguo Li, and Qiaodan Hu, In-situ observation on bubble evolution during laser powder bed fusion of oxide ceramic, Int. J. Miner. Metall. Mater., 32(2025), No. 6, pp.1451-1460. https://doi.org/10.1007/s12613-025-3170-2
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氧化物陶瓷激光粉床熔融过程中气泡演化的原位研究

摘要: 激光粉末床熔融技术(LPBF)在制备复杂结构、高致密度且性能优异的氧化物陶瓷领域展现出显著优势。然而,在LPBF过程中,熔池内气泡的形成和演化会在最终成型的陶瓷中形成孔隙缺陷,导致材料力学性能显著下降。因此,深入理解LPBF过程中的气泡动力学行为对提升产品质量至关重要。本研究采用同步辐射高速X射线成像技术,实现了Al2O3–Y2O3混合粉末床熔池内气泡动力学行为的原位观测,阐明了激光熔融过程中气泡的形成、生长、迁移和演化规律,揭示了熔池流动不稳定性与气泡破裂之间的内在关联。研究发现,气泡存在三种特征生长模式,即上浮主导的生长、气道附着式生长及气泡合并生长;大尺寸气泡破裂时会诱发熔体流动振荡,进而引发熔池局部失稳现象。该研究不仅深化了对LPBF过程中气泡动力学的认知,更为优化工艺参数、消除氧化物陶瓷孔隙缺陷提供了重要理论支撑。

 

In-situ observation on bubble evolution during laser powder bed fusion of oxide ceramic

Abstract: Laser powder bed fusion (LPBF) is used to fabricate complex-shaped, dense, and high-performance oxide ceramics. During LPBF, bubbles form and evolve in the melt pool and ultimately remain in the printed ceramics as pores, which significantly degrade the mechanical properties. Therefore, it is essential to understand the bubble behaviors during LPBF. Herein, we conducted an in-situ investigation of the bubble dynamics in the melt pool of homogeneously mixed Al2O3–Y2O3 powders using synchrotron high-speed X-ray imaging. The formation, growth, motion, and evolution of bubbles, as well as the relationship between the instability of melt flow and bubble rupture during LPBF, were elucidated. The findings reveal that bubbles from the interstices within the powder bed grow following three distinct modes, i.e., uplift growth, gas channel attachment, and bubble coalescence. Furthermore, melt flow oscillations caused by the bursting of large bubbles can lead to local instability of the melt pool. Results from this study enhance the understanding of bubble dynamics during LPBF and may provide valuable insights for pore elimination in LPBF-processed oxide ceramics.

 

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