Abstract
Understanding the morphology, composition and structural changes experienced by metallic glass powder particles upon laser powder bed fusion (LPBF) is the first step towards evaluating the impact of spatter generation on part quality and on feedstock degradation. This study presents the characterization of Zr-Cu-Al-Nb spatter particles by means of scanning and transmission electron microscopy with automated crystallographic orientation mapping and energy dispersive spectroscopy, and X-ray photoelectron spectroscopy. The powder exposed to the LPBF environment exhibits an average surface composition similar to the original feedstock, but with a rougher morphology. The typical spatter encountered in the remaining lack-of-fusion is a vapour-entrained particle, which probably underwent partial melting leading to the formation of α-Zr(O) dendrites, and “big-cube” Cu2Zr4O nanocrystals in its heat affected zone. In the present work, spatter characteristics are discussed considering glass properties and their connection to lack-of-fusion defects is addressed.
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