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<p>Laser-based powder bed fusion (L-PBF) of magnesium (Mg) and its alloys are expected to offer new prospects for functional additive manufacturing of temporary orthopaedic implants. The current study develops a comprehensive understanding of the interaction between laser and WE43 magnesium alloy by evaluating the individual and combined effects of varying laser parameters (laser power, exposure time, point distance, hatch spacing) on melt pool formation dynamics. It further investigates how energy density and each associated laser parameter influence melt pool behavior and interactions, which are key factors driving the densification of three-dimensional WE43 parts. A process map has been successfully developed through parameter optimisation, resulting in high-density (&gt; 99.5%) L-PBF WE43 parts. The study also determines the effect of L-PBF processing parameters on microstructural evolution characterised via scanning electron microscopy (SEM)/energy dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD) and electron backscatter diffraction (EBSD). As-built WE43 consisted of a non-homogeneous microstructure with fine grains and strong basal texture as well as widely dispersed secondary phases. An increase in the hardness was observed with increasing energy density from 20.83 to 128.57&#xa0;J/mm<sup>3</sup>.</p>

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Influence of process parameters on melt pool formation dynamics in laser powder bed fusion of dense WE43 magnesium alloy

  • 期刊论文

  • 发表日期：

    2025年9月15日

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  • Prathviraj Upadhyaya,
  • Sinéad M. Uí Mhurchadha,
  • Oliver J. McCarthy,
  • Tríona Kennedy,
  • Mert Celikin,
  • Ramesh Raghavendra

摘要

Laser-based powder bed fusion (L-PBF) of magnesium (Mg) and its alloys are expected to offer new prospects for functional additive manufacturing of temporary orthopaedic implants. The current study develops a comprehensive understanding of the interaction between laser and WE43 magnesium alloy by evaluating the individual and combined effects of varying laser parameters (laser power, exposure time, point distance, hatch spacing) on melt pool formation dynamics. It further investigates how energy density and each associated laser parameter influence melt pool behavior and interactions, which are key factors driving the densification of three-dimensional WE43 parts. A process map has been successfully developed through parameter optimisation, resulting in high-density (> 99.5%) L-PBF WE43 parts. The study also determines the effect of L-PBF processing parameters on microstructural evolution characterised via scanning electron microscopy (SEM)/energy dispersive X-ray spectroscopy (EDS), X-ray diffraction (XRD) and electron backscatter diffraction (EBSD). As-built WE43 consisted of a non-homogeneous microstructure with fine grains and strong basal texture as well as widely dispersed secondary phases. An increase in the hardness was observed with increasing energy density from 20.83 to 128.57 J/mm3.