Discontinuities in the laser powder bed fusion alloys: A review
There are several significant microstructural discontinuities in alloys produced by laser powder bed fusion (LPBF). This review focuses on the primary discontinuities arising in the LPBF manufactured alloys, including gas pores, lack of fusion (LOF), keyholes, cracks, and melt pools. It also examine...
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| Format: | Article |
| Language: | English |
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Elsevier
2025-07-01
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| Series: | Journal of Materials Research and Technology |
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| Online Access: | http://www.sciencedirect.com/science/article/pii/S2238785425016242 |
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| author | Mahdi Yeganeh Zahra Shahryari Mohammadreza Tavakoli Shoushtari Mostafa Eskandari |
| author_facet | Mahdi Yeganeh Zahra Shahryari Mohammadreza Tavakoli Shoushtari Mostafa Eskandari |
| author_sort | Mahdi Yeganeh |
| collection | DOAJ |
| description | There are several significant microstructural discontinuities in alloys produced by laser powder bed fusion (LPBF). This review focuses on the primary discontinuities arising in the LPBF manufactured alloys, including gas pores, lack of fusion (LOF), keyholes, cracks, and melt pools. It also examines the causes of these discontinuities, the effects of various factors, and techniques to reduce them. The structural integrity of LPBF-generated components is affected by these discontinuities. This review also mentions strategies to reduce or eliminate these defects to increase the reliability of the LPBF process. It shows that some defects can be minimized by choosing correct parameters, such as laser power and scan speed. However, some specific defects cannot be diminished by selecting parameters and require other options, such as post-treatments (e.g., heat treatment or hot isostatic pressing). Additionally, post-treatments and alloy composition modifications can help to adapt the material's characteristics and lower the discontinuity percentage. |
| format | Article |
| id | doaj-art-09be6e4d1a1540299377c0cef40d5021 |
| institution | Kabale University |
| issn | 2238-7854 |
| language | English |
| publishDate | 2025-07-01 |
| publisher | Elsevier |
| record_format | Article |
| series | Journal of Materials Research and Technology |
| spelling | doaj-art-09be6e4d1a1540299377c0cef40d50212025-08-20T03:33:27ZengElsevierJournal of Materials Research and Technology2238-78542025-07-01373193322910.1016/j.jmrt.2025.06.202Discontinuities in the laser powder bed fusion alloys: A reviewMahdi Yeganeh0Zahra Shahryari1Mohammadreza Tavakoli Shoushtari2Mostafa Eskandari3Corresponding author.; Department of Materials Science and Engineering, Faculty of Engineering, Shahid Chamran University of Ahvaz, Ahvaz, IranDepartment of Materials Science and Engineering, Faculty of Engineering, Shahid Chamran University of Ahvaz, Ahvaz, IranDepartment of Materials Science and Engineering, Faculty of Engineering, Shahid Chamran University of Ahvaz, Ahvaz, IranDepartment of Materials Science and Engineering, Faculty of Engineering, Shahid Chamran University of Ahvaz, Ahvaz, IranThere are several significant microstructural discontinuities in alloys produced by laser powder bed fusion (LPBF). This review focuses on the primary discontinuities arising in the LPBF manufactured alloys, including gas pores, lack of fusion (LOF), keyholes, cracks, and melt pools. It also examines the causes of these discontinuities, the effects of various factors, and techniques to reduce them. The structural integrity of LPBF-generated components is affected by these discontinuities. This review also mentions strategies to reduce or eliminate these defects to increase the reliability of the LPBF process. It shows that some defects can be minimized by choosing correct parameters, such as laser power and scan speed. However, some specific defects cannot be diminished by selecting parameters and require other options, such as post-treatments (e.g., heat treatment or hot isostatic pressing). Additionally, post-treatments and alloy composition modifications can help to adapt the material's characteristics and lower the discontinuity percentage.http://www.sciencedirect.com/science/article/pii/S2238785425016242Laser powder bed fusion (LPBF)Gas poresLack of fusionKey holesCracksMelt pool |
| spellingShingle | Mahdi Yeganeh Zahra Shahryari Mohammadreza Tavakoli Shoushtari Mostafa Eskandari Discontinuities in the laser powder bed fusion alloys: A review Journal of Materials Research and Technology Laser powder bed fusion (LPBF) Gas pores Lack of fusion Key holes Cracks Melt pool |
| title | Discontinuities in the laser powder bed fusion alloys: A review |
| title_full | Discontinuities in the laser powder bed fusion alloys: A review |
| title_fullStr | Discontinuities in the laser powder bed fusion alloys: A review |
| title_full_unstemmed | Discontinuities in the laser powder bed fusion alloys: A review |
| title_short | Discontinuities in the laser powder bed fusion alloys: A review |
| title_sort | discontinuities in the laser powder bed fusion alloys a review |
| topic | Laser powder bed fusion (LPBF) Gas pores Lack of fusion Key holes Cracks Melt pool |
| url | http://www.sciencedirect.com/science/article/pii/S2238785425016242 |
| work_keys_str_mv | AT mahdiyeganeh discontinuitiesinthelaserpowderbedfusionalloysareview AT zahrashahryari discontinuitiesinthelaserpowderbedfusionalloysareview AT mohammadrezatavakolishoushtari discontinuitiesinthelaserpowderbedfusionalloysareview AT mostafaeskandari discontinuitiesinthelaserpowderbedfusionalloysareview |