High Power Laser and Particle Beams, Volume. 37, Issue 7, 071001(2025)
In-situ characterization of metal laser additive manufacturing using a laser-driven X-ray source
Pore defects in metal laser additive manufacturing (AM) typically originate and evolve within the melt pool, exhibiting microscopic and highly transient characteristics. High spatiotemporal resolution X-ray imaging provides a powerful tool for in situ characterization of these processes, which is essential for understanding defect formation mechanisms and optimizing processing parameters. In this study, a high spatiotemporal resolution X-ray imaging technique tailored for metal laser AM was developed utilizing Betatron radiation generated by an ultra-intense, ultrashort pulsed lasers. This technique was employed to perform in-situ characterization of micro-melt pools under various processing conditions. The results show that the Betatron X-ray source allows real-time imaging of melt pool and keyhole dynamics in metal samples with thicknesses on the order of hundreds of micrometers, achieving a spatial resolution of 4 μm. These findings provide a solid foundation for the future application of laser-driven X-ray sources in investigating defect formation mechanisms and advancing process optimization in metal laser AM.
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Jiaxing Wen, Hang Guo, Sixin Wu, Tao Zhu, Gaojie Zeng, Mao Peng, Sijie Fan, Hansheng Ye, Qiang Gong, Lai Wei, Quanping Fan, Xiangjun Xiang, Song Li, Shaoyi Wang, Yue Yang, Jianmeng Wei, Hao Wang, Yinlong Zheng, Xianfeng Shen, Jiayi Qian, Jiacheng Zhu, Zongxin Zhang, Yuchi Wu, Wentao Wang, Yi Xu, Shuke Huang, Zongqing Zhao. In-situ characterization of metal laser additive manufacturing using a laser-driven X-ray source[J]. High Power Laser and Particle Beams, 2025, 37(7): 071001
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Received: Jun. 15, 2025
Accepted: Jul. 8, 2025
Published Online: Jul. 18, 2025
The Author Email: Zongqing Zhao (zhaozongqing99@caep.cn)