On the role of thermal fluid dynamics into the evolution of porosity during selective laser melting

Thermal fluid dynamics and experiments have been used to study the evolution of pores during selective laser melting of Ti-6Al-4V. Scanning electron micrographs show that the morphology of pores changed from near-spherical to elongated shape as the laser scan speed increased. Computational fluid dynamics suggests that this is caused by the change of flow pattern in the melt pool which is dictated by forces such as vapour pressure, gravitational force, capillary and thermal capillary forces exerted on the metallic/gaseous interface.