Direct observation of crack formation mechanisms with operando Laser Powder Bed Fusion X-ray imaging

Laser powder bed fusion (L-PBF) is a versatile additive manufacturing process that can print geometrically complex metal parts for variety of applications. However, poor control defect formation during processing hampers its widespread industrial adoption. Many materials suffer from high crack susceptibility L-PBF, which results in degraded mechanical properties, and an obstacle to the certification critical parts. In order unveil mechanisms prone-to-cracking nickel-based superalloy, we employ high-speed synchrotron X-ray imaging combination with miniaturized L-PBF set-up reproduces real conditions. This unique provides operando L-PBF. Complementary post-mortem inspection morphology thermal simulations supported by diffraction-based measurements temperature evolution allow identify cracking mechanism differentiate solidification liquation.