In-situ detection of stochastic spatter-driven lack of fusion: Application of optical tomography and validation via ex-situ X-ray computed tomography

The presence of random defects in laser powder bed fusion (LPBF) parts is an issue that challenges the reliability this manufacturing process and hinders its employment structural, defect-sensitive components. A potential solution to increase LPBF employing in-process monitoring targeting defect detection. This study aims detect stochastic driven by spatter particles via in-situ validate detection method ex-situ X-ray computed tomography (XCT). By means optical (OT), images were registered layerwise during Hastelloy X specimens. analyzed spatters landing within specimen boundaries, spatial coordinates detections obtained. specimens also measured XCT, from which key features internal was then compared XCT measurements. It found 79 % lack detected OT images. particularly successful for large defects. Spatter-induced present manufactured with optimized processing parameters different degrees, depending on robustness conditions spatters. demonstrates applicability indirect fusion, whose inferred redeposits bed.