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

Jiaxing Wen1, Hang Guo3, Sixin Wu1, Tao Zhu2, Gaojie Zeng3, Mao Peng1, Sijie Fan1, Hansheng Ye1, Qiang Gong2, Lai Wei2, Quanping Fan1, Xiangjun Xiang1, Song Li3, Shaoyi Wang1, Yue Yang1, Jianmeng Wei3, Hao Wang3, Yinlong Zheng3, Xianfeng Shen2, Jiayi Qian3, Jiacheng Zhu3, Zongxin Zhang3, Yuchi Wu1, Wentao Wang3, Yi Xu3, Shuke Huang2, and Zongqing Zhao1、*
Author Affiliations
  • 1Laser Fusion Research Center, CAEP, Mianyang 621900, China
  • 2Institute of Mechanical Manufacturing Technology, CAEP, Mianyang 621900, China
  • 3Shanghai Institute of Optics and Fine Mechanics, Chinese Academy of Sciences, Shanghai 201800, China
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    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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    Paper Information

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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)

    DOI:10.11884/HPLPB202537.250191

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