Analysis of morphology and residual porosity in selective laser melting of Fe powders using single track experiments

Abstract

Morphology and residual porosity of single tracks obtained by pulse selective laser melting (SLM) of Fe powder have been studied by metallography. Multiple cross sections of the stainless substrate with the single tracks deposited by SLM are examined and classified depending on processing parameters. A sustainable scanning strategy to reduce residual porosity is suggested for pulse laser annealing. The developed method is suitable both for improvement of processing regimes in commercial SLM machines and validation of numerical models in additive manufacturing of metal parts. The effect of the beam radius, pulse energy, its frequency and duration on a shape of the single track and its adhesion to the substrate is revealed.