Increasing Laser Power Research Articles

Optimization of Surface Finish of Plasma Metal Deposited Stainless Steel 316L Parts by Utilization of Plasma Beam Remelting (PBR) and Taguchi Methodology

The study aimed to optimize the Plasma Beam Polishing process for 316L stainless steel components to reduce anisotropy and poor surface roughness using statistical analysis. An experimental design investigated the impacts of managing factors on surface roughness, with scanning speed having the ultimate impact, followed by beam power and energy density. For lower values of plasma energy density and scanning speed, and a focal location without changes on the metal surface, there was a strong tendency for the estimated Ra to drop with increasing laser power. The process parameters were changed throughout a broad range of values, making it challenging to model the dependent variable across the whole range of experimental trials. The study supports the potential of PBP as a post-processing method for additive manufacturing components.

Laser‐Crystallization of TiO2 Nanotubes for Photocatalysis: Influence of Laser Power and Laser Scanning Speed

AbstractTitanium dioxide (TiO2) nanotubes have raised significant attention in the field of photocatalysis. However, achieving locally‐confined, tunable, and efficient crystallization remains challenging. Laser crystallization that enables surface‐confined, fast, and localized annealing has emerged as an alternative to calcination of TiO2 nanotubes. Nonetheless, questions regarding crystallization parameters and mechanism remain open. In this work, amorphous TiO2 nanotubes are synthesized by a two‐step anodization process and laser exposed (515 nm, 1 MHz, 250 fs, 256–569 mW, 1–200 mm s−1) to study the impact of laser parameters and the mechanism of laser crystallization. A thorough analysis via Raman spectroscopy, X‐ray diffraction, scanning electron microscopy, UV–vis spectroscopy, transmission electron microscopy, and degradation of methylene blue is performed and the influence of laser processing parameters on the crystallization are studied and discussed. As laser power increases, a gradual transition from amorphous to anatase and rutile phase takes place, consistent with a thermal crystallization mechanism. Contrary, with increasing laser scanning speeds, thus lower pulse numbers, anatase is converted to rutile and melting occurs. The degradation of methylene blue with anatase samples crystallized by laser and calcination exhibits equal kinetic degradation constants of 0.013 s−1cm−2. This study enhances the understanding of laser crystallization of TiO2 nanotubes.

A numerical and experimental analysis of CO2 laser micro-milling on PMMA sheet considering a multipass approach for microfluidic devices

Laser-assisted machining is an advanced manufacturing process that provides excellent cutting quality, flexibility, and precision. The current study used a CO2 laser to create microchannels in polymethyl methacrylate (PMMA) sheets using a series of laser passes by varyingparameters such as laser power (30–40 Watt), number of passes (1–4), and cutting speed (20–25 mm/s). A finite element analysis is performed using ABAQUS with subroutines such as Distributed Flux (DFLUX) and User Defined Field (USDFLD) to simulate and predict the upper and lower kerf width, kerf angle, and heat-affected zone (HAZ) during the process. Thermal analysis has been performed by considering the laser beam as body heat flux with a moving heat source. It has been observed that the HAZ tends to reduce with the increase of laser cutting speed. During the laser cutting process, the upper kerf width is found to increase with increasing laser power, as well as with increasing the number of passes at a given laser power and cutting speed. It is also predictedthat when laser cutting speed increases, the kerf width for a given laser power decreases. The experimental and simulation results are in good agreement and the results demonstrated thatthe average percentage error in HAZ, kerf angle,upper kerf, and lower kerf width was 3.21 %, 5.06 %, 7.60 %, and 22.2 %, respectively. The results of this study have significance for the advancement of precise and state-of-the-art manufacturing for application in microfluidic devices.

Effect of laser power on the structure and wear performance of laser additively manufactured Cu45Zr45Al6Ti4 metallic glass coating

Laser powder bed fusion (LPBF) technology presents significant potential for the production of metallic glass (MG) coatings. This work investigated the influence of laser power on the structure and wear performance of a CuZr-based metallic glass coating with composition of Cu45Zr45Al6Ti4 on Ti substrate. It was observed that the melt pool, which serves as the fundamental building block for constructing MG coatings in LPBF, undergoes a transition from conduction mode to keyhole mode, and subsequently to extended mode with increasing laser power. The MG coatings prepared using low power laser (140 W) and medium power laser (240 W) both exhibited a nearly fully amorphous state. However, at a laser power of 360 W, noticeable crystallization occurred in the coating, as evidenced by SEM observation. The wear rate of Cu45Zr45Al6Ti4 MG coating was measured to be 4.67 × 10−6 mm3·N−1·m−1, which is significantly lower than that of the Ti substrate (6.38 × 10−4 mm3·N−1·m−1). This study reveals the relationship between the laser power and morphology of the melt pool, as well as the structure and wear performance of the LPBF-fabricated MG coatings, offering guidance for optimizing the laser additive manufacturing process of wear-resistant MG coatings.

A new phenomenon in a selective laser melted 316L stainless steel with a wider and higher laser energy density

Defects, boundaries, textures, tensile properties, fractographies, sub-grains, nano-oxide particles, and deformation twins in selective laser melted 316L stainless steel (SLM316LSS) were systematically characterized as functions of laser energy density. The defects, boundaries, textures of the as-built SLM316LSS were shown to depend largely on the applied laser power. The porosity of the SLM316LSS significantly decreased with the increase laser power from 70 to 140 W (corresponding to the laser energy density from 116.7 to 233.3 J/mm3), while exhibiting a slight increase in the laser power range of 140–280 W (the laser energy density of 233.3–466.7 J/mm3). Additionally, the SLM316LSS specimen at a laser power of 140 W reached the hardness of ∼252 HV, the yield strength of ∼605 MPa and the ultimate tensile strength of ∼710 MPa, along with the elongation to fracture of ∼32.5%, respectively, due to the lowest defect concentration and the presence of twin boundaries and textures, combined with SiO2 nano-oxide particles and deformation twinning. However, the crack appeared in the SLM316LSS within the laser power range from 210 to 280 W (the laser energy density from 350.0 to 466.7 J/mm3), and the mean crystallite size was more than 50 μm, which insignificantly affected the mechanical properties of the steel compared with a laser power of 140 W.

One-step sustainable preparation of laser induced S-doped graphene for assembly of high-performance supercapacitors

Lignin, an industrial by-product that is abundant, renewable and has aromatic ring characteristics, is regarded as an ideal raw material for the synthesis of two-dimensional graphene materials. However, the sustainable development of graphene produced from lignin faces thorny challenges such as environmental pollution, low yield, cumbersome steps and harsh conditions. In this study, low-energy, green, large-scale one-step preparation of sulfur-doped graphene was achieved by co-blending lignin and sodium alginate into a fully biomass-based film, followed by easy-to-operate laser etching. Among them, alkaline lignin not only served as a carbon source but also acted as a sulfur doping source, avoiding the use of additional sulfur doping reagents. The results showed that the sheet resistance of graphene gradually decreased with the increase of laser power. The sheet resistance of graphene prepared when the laser power was 90% was as low as 8 Ω sq−1, which provided an inherent advantage for the subsequent assembly of flexible micro-supercapacitors. The specific capacitance and high energy density of the resulting supercapacitor were as high as 88.29 mF cm−2 and 12.26 μW h cm−2, respectively. This method successfully developed a sustainable and low-energy graphene preparation method, paving the way for the sustainable development of flexible energy storage devices.

Analysis of laser-induced surface damage of single-crystal Ni-based superalloy towards improving machinability

Single-crystal (SC) nickel-based superalloys provide improved high-temperature strength, and resistance to creep, fatigue and oxidation, compared to equiaxed and columnar-grained components due to their higher solid solution strengthening, precipitation hardening and the absence of grain boundaries. However, the SC nickel-based superalloys are ‘difficult-to-cut’. To enhance the machinability, a concept of laser-induced surface damage (LISD)-assisted machining is being studied. Laser surface modification (LSM) experiments were been performed by employing the design of experiments (DoE) strategy L18, OA (orthogonal array). The LSMed geometries were characterized to identify various laser-induced surface defects including solidification cracks, microcracks, micropores, microstructural changes, phase changes, recrystallization, and deformation. Further, parametric interactions and optimization of the process parameters were performed to manufacture a larger LISD layer. The parameter-structure-property relationship was derived systematically and the mechanisms of LISD on the SC nickel-based superalloy were described in details. The results indicate that the LISD increase with an increase in laser power followed by a decrease in scan speed and beam diameter. LISD geometries possess 1 % to 4 % of crack density and lower hardness of around 27 % than the base metal. Slot milling experiments were then conducted on the LISD specimens, which showed up to a 40 % reduction in cutting forces when compared to untreated specimens. It is evident that this methodology can be adopted to further improve the machinability of various difficult-to-cut materials.

Low-voltage solution-processed NaxCu1−xI thin-film transistors for mimicking synaptic plasticity

In this article, NaxCu1−xI thin-film transistors gated by chitosan for low-voltage operation have been created by doping CuI with different Na concentrations (x = 0, 0.05, 0.1). It is found that the devices exhibit optimal performance when x is 0.05: a large current on/off ratio of 1.62 × 105, a steep subthreshold slope of 17.72 mV/dec, a saturation field-effect mobility of 0.51 cm2/V s, and a threshold voltage of 1.10 V. The operating voltage of the devices is reduced to below 2 V due to the electric-double-layer (EDL) effect. At a frequency of 10 Hz, a maximum specific capacitance of 1.36 μF/cm2 can be obtained in the chitosan. The effects of bias stress and laser on Na0.05Cu0.95I thin-film transistors (TFTs) have been examined at the end of the article, and the results revealed that Na0.05Cu0.95I TFTs possess good stability. As the bias stress gets longer and the laser power increases, the transfer curves of TFTs shift positively. Also, artificial synaptic behaviors and functions have been simulated experimentally. It can be divided into single-pulse, double-pulse, and multiple-pulse. According to the experimental results, features such as short-term plasticity, long-term plasticity, paired-pulse facilitation, high-pass filtering, pulse logic, and spatial summation have been achieved. The electrostatic modulation of EDL due to proton transverse migration is vital for this simulation. The realization of low-voltage synaptic Na0.05Cu0.95I TFTs prepared by solution method with pulse logic and spatial summation functions is crucial for application of portable biosensors and neuromorphic systems.

The Effect of Process Parameters on the Temperature and Stress Fields in Directed Energy Deposition Inconel 690 Alloy.

Additive manufacturing (AM) technology has the advantages of designability, short process times, high flexibility, etc., making it especially suitable for manufacturing complex high-performance components for high-end industrial systems. However, the intensive temperature gradients caused by the rapid heating and cooling processes of AM can generate high levels of residual stresses, which directly affect the precision and serviceability of the components. Taking Inconel 690 alloy, which is widely used in nuclear power plants, as the research object, a thermo-coupled mechanical model of temperature field and residual stress field of directed energy deposition (DED) of Inconel 690 was established based on ABAQUS 2019 finite element software to study the influence of process parameters on the temperature history and the distribution of residual stresses in the DED process. The experimental results show that the peak temperature of each layer in the fabrication process increases with the increase in laser power and preheating temperature, and decreases with the increase in scanning speed and interlayer dwell time. Substrate preheating only has a large effect on the peak temperature of the first four layers. Residual stresses are mainly concentrated in the upper and middle parts, the bottom of the substrate, and the sides combined with the substrate, and the residual stresses increase with the increasing laser power and decrease with the increasing interlayer dwell time. Decreasing laser power, longer dwell time, higher preheating temperature, and appropriate scanning speed are beneficial for the reduction in residual stresses in Inconel 690 components. This research has important significance for the process design and residual stress modulation in the additive manufacturing of Inconel 690 alloy.

An experimental study on the effect of CO2 laser powers on melting characteristics of clear ice – Part II: Vertical irradiation

Icing phenomenon widely exists and plays negative effects in aviation and electricity fields. Laser deicing technology is a typical non-contact and high-efficiency deicing method. To accurately predict and control the laser-induced ice melting process, an experimental study on melting characteristics of clear ice under vertical CO2-laser irradiation and natural convection is carried out, with the laser power varied at a range of 20–60 W. As resulted, the axial melting rate tends to increase and then decrease with the increase of laser power. The maximum of average and instantaneous axial melting rate at 40 W are 5.85 mm/s and 13.95 mm/s, respectively. The higher the laser power, the larger the peaks of maximum melting length. At 20 W and 60 W, the peaks of maximum melting length are 10.51 mm and 12.19 mm, respectively. There is little correlation between the deflection of angle and laser power. At 30 W and 50 W, the maximum angles of melting length are 0.77° and 2.52°, respectively. When the melting depth is smaller than 81.5 mm, the maximum energy efficiency at 20 W is 64.8 %, while when it is greater than 81.5 mm, the maximum energy efficiency at 60 W is 63.6 %. Results of this study are meaningful for the optimization of laser deicing technology.

Evolution mechanism of scratch removal based on the implementation of magnetorheological finishing.

Scratches on optical components induce laser damage and limit the increase in laser power. Magnetorheological finishing (MRF) is a highly deterministic optical manufacturing technology that can improve the surface roughness of optical components. Although MRF has exhibited significant potential for reducing subsurface damage and removing scratches, the principle and mechanism behind the scratch removal are not sufficiently understood. In this study, the theory of fluid mechanics is used to analyze the pressure, velocity, and particle trajectory distribution near a scratch. A physical model was developed for the differential removal of scratches at the bottom and surface of the optical components. The morphological evolution of the scratch was predicted during removal, and detailed experiments were performed to verify the effectiveness of the proposed model. The results indicate that scratches expand laterally rather than being completely removed. Furthermore, scratch removal efficiency is greater when the removal direction is perpendicular to the scratch rather than being parallel. This study offers an intrinsic perspective for a comprehensive understanding of the MRF technique used for scratch removal, which can be beneficial for removing scratches from aspherical optical systems.

Calculation and measurement of trapping stiffness in femtosecond optical tweezers.

Due to the characteristics of ultra-short pulse width and ultra-high peak power, femtosecond pulse laser can effectively induce nonlinear optical effects in trapped objects. As a result, it holds great value in the fields of micro and nano manipulation, microfluidics, and cell biology. However, the nonlinear optical effects on the stiffness of femtosecond optical traps remain unclear. Calibration of trap stiffness is crucial for accurately measuring forces and manipulating small particles. In this paper, we compare the stiffness between femtosecond optical traps and continuous wave optical traps. Experimental results demonstrate that the stiffness of the femtosecond optical trap in the splitting direction is greater than that in other directions and the stiffness of the continuous wave optical trap under the same laser power condition. Additionally, as the laser power increases, the stiffnesses of both the femtosecond optical trap and the continuous wave optical trap gradually increases. In contrast to a linear increase of the continuous wave optical trap, the stiffness of the femtosecond optical trap exhibits an exponential rise with increasing laser power. This research provides guidance and reference for improving the force measurement accuracy of femtosecond optical tweezer system.

The Effect of Laser Power on the Microstructure and Wear Resistance of a Ni3Al-Based Alloy Cladding Layer Deposited via Laser Cladding

A coating prepared via laser cladding has the advantages of a high-density reinforced layer, a low matrix dilution rate, and combination with matrix metallurgy. In this study, Ni3Al-based alloy cladding layers with Cr7C3 were prepared via laser cladding, and the corresponding microstructures and wear resistance were studied in detail. The results show that the Ni3Al-based cladding layer prepared using laser cladding technology had good metallurgical bonding with the matrix, and there were no pores, cracks, or other defects on the surface. The microstructures of the laser cladding layer were mainly γ′-Ni3Al, β′-NiAl, and in situ C7C3. As the laser power increased, the heat input increased, resulting in an increase in the dilution rate. Simultaneously, the carbide size in the laser cladding layer increased. With the increase in laser power, the hardness of the laser cladding layer of the Ni3Al-based alloy decreased, and the wear resistance of the laser cladding layer first strengthened and then weakened. When the laser power increased to 2.0 kW, the wear rate of the laser cladding layer decreased to 0.480 × 10−5 mm3/N·m. When the laser power increased to 2.4 kW, the wear rate of the laser cladding layer increased to 0.961 × 10−5 mm3/N·m, which was twice the rate at 2.0 kW. This could be attributed to small Cr7C3 particles, which could not effectively separate the wear pairs, resulting in more serious adhesive wear. Large Cr7C3 particles caused the surface of cast iron material with lower hardness to be damaged, which suffered more serious particle wear. The generation of short rod-shaped carbides should be avoided because, in the process of friction and wear, carbides with these shapes are easy to break, thus leading to crack initiation.

Nonlinear optical effects in polycrystalline transparent Al2O3 ceramics using femtosecond laser pulses—supercontinuum generation and laser damage

Nonlinear optical properties play a key role in technologies such as broadband laser light sources and ultrafast laser machining. With the emergence of transparent nanocrystalline Al2O3 ceramics as an alternative to single crystal alumina (sapphire), it is critical to understand their nonlinear optical behavior. Here, we report the demonstration of supercontinuum generation in polycrystalline alumina ceramics. Substantial broadening was observed when a focused 515 nm pulsed (260 fs) laser propagated through the ceramic sample. The broadening increased with increasing laser power and displayed stokes/anti-stokes asymmetries. At higher incident power, permanent damage was observed. Our results show that transparent nanocrystalline Al2O3 ceramics have a higher material removal rate than single crystal alumina. These results have interesting implications for laser machining as well as integrated photonics.

Laser-induced changes on the upconversion luminescence properties of BiF3:Yb,Er nanoparticles

BiF3 nanoparticles doped with Yb3+ and Er3+ ions in varying ratios were prepared by co-precipitation method and its upconversion luminescence (UCL) properties were investigated in detail before and after high-intensity laser treatment. Green-to-red ratio (GRR) of luminescence from cubic-BiF3:Yb,Er nanoparticles is found to increase with an increase in laser power for as prepared sample. Unlike this, for conventional Yb,Er doped upconversion nanoparticles (UCNPs) such as cubic NaYF4:Yb,Er and hexagonal-NaYF4:Yb,Er, a decrease in GRR values is observed with an increase in laser power. This has been explained based on the reduced extent of Er3+-Er3+ interaction in BiF3:Yb,Er nanoparticles compared to that existing in cubic and hexagonal forms of NaYF4:Yb,Er, nanoparticles. Reduced interaction is brought about by higher lattice parameter of BiF3 host compared to the NaYF4 host which leads to a lesser extent of cross-relaxation in the former host thereby favoring the population of 4S3/2 and 2H11/2 levels of Er3+. Effect of high-intensity laser (180W/cm2) irradiation on BiF3:Yb,Er nanoparticles resulted in an irreversible five-fold increase in upconversion luminescence intensity and this is attributed to combined effect of partial conversion of BiF3 to cubic Bi2O3 and removal of adsorbed water molecules. These inferences are confirmed by XRD and TEM measurements carried out on laser-treated sample. Improved luminescence intensity from the laser-treated sample is also confirmed by the high-contrast clear images obtained from impressions made using high-intensity laser irradiation on BiF3:Yb,Er nanoparticles. BiF3:Yb,Er nanoparticles showed an excellent thermal sensitivity of 0.3% K−1 at room temperature and the value is comparable with that of conventional β-NaYF4:Yb,Er nanoparticles.

Optimization of structure and properties of WC-reinforced FeCoNiCr high-entropy alloy composite coating by laser melting

High entropy alloys have the potential to be used as coating materials in many fields due to their excellent mechanical properties, corrosion resistance and high-temperature stability. Based on the application requirements of high-entropy alloys, this study aims to explore how tungsten carbide can optimize the properties of high-entropy alloys. Through theoretical research and experimental validation, the effects of the organizational structure of high-entropy alloy coatings on their properties and the effects of tungsten carbide content on the properties of high-entropy alloy coatings were investigated. The micro hardness of the coatings is relatively high at low power laser melting, while it decreases with the increase of laser power. After laser melting of different materials, the average impact toughness of the studied materials exceeded 70 J/cm2, and the average values of microhardness of the optimized coatings prepared at laser powers of 1400 W and 1600 W were more than 160 HV0.2. In addition, the properties of the high-entropy alloys were significantly improved when the content of tungsten carbide reached a certain percentage. The composite coatings have excellent wear resistance, corrosion resistance and thermal stability. Overall, the optimized tungsten carbide on high entropy alloys in this study has good performance, which is of great theoretical and practical significance for understanding the performance regulation and optimal design of high entropy alloy coatings.

Finite element simulation analysis of flow heat transfer behavior and molten pool characteristics during 0Cr16Ni5Mo1 laser cladding

0Cr16Ni5Mo1 super martensitic stainless steel has excellent weldability and is an economical material with a high life cycle and low cost, but there are few researches and applications of this material in additive manufacturing. In order to realize the application of 0Cr16Ni5Mo1 large-area laser cladding technology, the multi-track lap cladding of the material was studied. In this work, a multi-physical finite element model of multi-layer multi-track laser cladding was established, taking into account thermodynamic processes such as phase transition, Marangoni convection, and buoyancy. The flow and heat transfer behavior of 0Cr16Ni5Mo1 in multi-layer multi-track laser cladding process and the characteristics of the molten pool are studied. The research focused on the flow heat transfer behavior and molten pool characteristics of 0Cr16Ni5Mo1 during multi-layer multi-track laser cladding. The discussed aspects include the evolution history of the temperature field within the molten pool, flow field characteristics, molten pool dimensions, and dilution ratio under various laser powers and overlap rates. The results show that with the increase of overlap rate, the morphology of molten pools in different clad tracks will also change, and the flow rate, dilution ratio, and length of molten pools in the second track are negatively correlated, while the temperature and height of molten pools are positively correlated. As the laser power increases, all the characteristic quantities are positively correlated with it.

Towards the hydrogen pore in additively manufactured AlMgScZr alloy: influencing factors, formation kinetics mechanism

Hydrogen pores in laser additive manufacturing (LAM) aluminum alloys have long been a major challenge for its application. In this study, the formation mechanisms of hydrogen pores and its kinetic behaviors were systematically investigated in laser directed energy deposited (L-DED) AlMgScZr alloy. The results indicated that hydrogen pores accumulated layer by layer at the melt pool boundaries, due to the high nucleation rate and insufficient time to escape of hydrogen pores at the melt pool boundaries. Dring the AlMgScZr powder at 150 °C/4 h enabled the significant decrease of moisture content from 0.0520 wt% to 0.0096 wt%, while the porosity of the L-DED sample only decreased from 0.51% to 0.36%. The increase of laser power decreased the porosity of L-DED sample. Except the L-DED parameters, the alloy composition exerted a more significant influence on hydrogen porosity. When the Mg content increased from 9 wt% to 14 wt%, the porosity exhibited an increase from 0.36% to 0.52%. Conversely, the incorporation and subsequent augmentation of Si content resulted in a significant reduction in porosity, reaching as low as 0.15% with an increase to 2 wt%. The solubility and diffusion coefficient of [H] in Al-Mg-Sc-Zr melt with different Mg and Si contents were calculated by density functional theory (DFT). It was observed that increasing the Si content led to a decrease in the nucleation zone for hydrogen pores and reduced porosity. A comprehensive porosity inhibition strategy that combines powder drying, process optimization, and composition regulation have been developed.

Effect of laser remelting on internal defects and properties of Ni-based coatings reinforced by multi-channel WC in situ

In order to investigate the effect of laser remelting on the properties of hot work die steel, WC reinforced Ni base remelting layer was prepared on H13 steel surface. Optical metallography microscope, X-ray diffractometer and scanning electron microscope were used to analyze the macroscopic defects, phase evolution and microstructure of the coating before and after laser remelting. Microhardness tester and friction and wear tester were used to test the microhardness and wear resistance of the remelted layer, and compared with the coating without remelting. The results show that the inner porosity of the coating decreases with the increase of laser power. With the dissolution of WC/W2C ceramic particles and the uniform distribution of W element, the distribution of reinforcement particles in the coating becomes more and more uniform. When the laser power reaches 1500 W, the WC/W2C ceramic particles inside the coating basically disappear, the porosity is reduced to the lowest, the coating uniformity is the best, and the microhardness and wear resistance are the highest.

Effect of Spatter Behavior on Mechanical Properties and Surface Roughness of Printed Parts during PBF-LM of 316L.

The spatter generated by the interaction between laser and powder during Powder Bed Fusion-Laser Melting (PBF-LM) can significantly affect the quality of printed parts. A high-speed camera is used to observe the dynamic process of spatter's behavior under different layer thickness and laser powers during the printing process, and to analyze the printed samples' surface roughness, microstructure, and mechanical properties. In terms of spatter image processing, employing an optical flow approach to track and quantify the number of spatters efficiently eliminates statistical redundancy and improves statistical correctness. It is found that under the same laser power, the number of spatters produced by the laser scan direction with the gas flow (LSD-W) is more than that by the laser scan direction against the gas flow (LSD-A), and the number of spatters produced increases with the increase of laser power. Analyzing the mechanical properties and surface roughness of the printed samples under different process parameters quantitatively reveals that differences in the spatter amount generated under different process parameters in the PBF-LM process is not the determining factor affecting the difference in tensile strength of printed parts. During LSD-W, the number of spatters generated at laser power of 170 W and layer thickness of 0.03 mm is 87, and the tensile strength of the printed sample is 618 MPa. During LSD-W, the number of spatters generated at laser power of 320 W and layer thickness of 0.05 mm is 211, and the tensile strength of the printed sample is 680 MPa. Instead, spatter generation has a more direct impact on the surface roughness of printed parts. The layer thickness is 0.03 mm, the laser power is 170 W, and (Ra = 2.372 μm) is the surface roughness of the sample. The layer thickness is 0.05 mm, the laser power is 320 W, and (Ra = 8.163 μm) is the surface roughness of the sample.