Pore Formation in Laser-Assisted Powder Deposition Process

Pore formation remains a concern in the area of rapid manufacturing by the laser engineered net shaping process. Results usually conflict on the origin of these pores; whether it should stem from an effect due to the physical/mechanical properties of the material or from an effect purely related to the processing parameters. We investigated this problem spanning a range of process parameters for deposition and using three different material powders, namely, an AISI 410 grade stainless steel, AISI 316L grade stainless steel, and AISI 4140 grade medium-carbon low alloy steel. The volume fraction, number density, and size distribution of pores were quantified using X-ray computed tomography and optical microscopy. Pores formed both at the interface between the adjacent layers and within the bulk of the layer. They were systematically sensitive to both the powder material composition and the process parameters.