Particle Inertia-Driven Pore Formation over Material Property Effects in Laser Powder-blown Directed Energy Deposition

Abstract

Laser Powder-blown Directed Energy Deposition (LP-DED) offers flexibility for process and materials and high productivity (~5 kg/h), but process-induced pores often compromise mechanical properties. This study utilizes in-situ X-ray synchrotron imaging to compare pore formation mechanisms in Ti-6Al-4V (Ti64) and stainless steel 316L (SS316L), focusing on the interplay between particle dynamics and thermophysical properties. Four distinct pore formation mechanisms were identified, with most large pores originating from the closure of cavities formed behind incident particles impinging on the melt pool. High Weber number (We>>1) governs this behavior, indicating that particle inertia, rather than thermophysical property differences, is the primary driver of large pore formation. The study demonstrates that increased energy density leads to larger melt pool volumes, facilitating deeper particle penetration. This greater penetration depth directly correlates with increased pore diameters. While thermophysical properties secondarily influence pore-formation frequency and cavity symmetry, particle inertia remains the dominant factor. These findings provide a physically grounded basis for understanding and controlling porosity in powder-blown DED processes.