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This paper gives an insight into the complex topic of defect formation, analysis, and prevention in laser-based manufacturing, addressing challenges in both fusion welding and defect control in additive manufacturing (AM). The research combines experimental studies, advanced analysis techniques, and numerical simulations to understand the underlying mechanisms that can lead to the failure of a part in operation. Three different case studies are discussed: laser welding of dissimilar aluminium (Al) copper (Cu) connections used in electric vehicle battery manufacturing, Direct Energy Deposition with Laser Beam (DED-LB), and Laser Powder Bed Fusion (PBF-LB) with a hot isostatic press (HIP) post-processing step. Among common analysis techniques, including metallography, microscopy, tensile testing, electrical resistance, and hardness measurements, in case study 1, high-temperature confocal laser-scanning microscopy (HT-cLSM) is used to observe in situ changes in the characteristic microstructure of Al-Cu joints. In case study 2, a digital twin approach to find and mitigate anomalies in a DED-LB process shows how defect control in an AM process can be realized. Finally, in case study 3, a pore tracing analysis through X-ray CT scanning before and after the HIPing process of AlSi10Mg cylinders manufactured with PBF-LB/w shows that regardless of the initial shape, all pores tend to shrink in size and become irregularly shaped. In summary, this work provides valuable insights into various strategies for optimization of manufacturing processes and design of more robust processes, materials, and structures through defect mitigation.

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From Pores to Brittle Phases: Defect Mitigation in Laser-Based Manufacturing

  • 会议论文

  • 发表日期：

    2026年

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  • Clemens Obergfell,
  • Sebastian Hartmann,
  • Natan Nudelis,
  • Michael Brandner,
  • Peter Mayr

摘要

This paper gives an insight into the complex topic of defect formation, analysis, and prevention in laser-based manufacturing, addressing challenges in both fusion welding and defect control in additive manufacturing (AM). The research combines experimental studies, advanced analysis techniques, and numerical simulations to understand the underlying mechanisms that can lead to the failure of a part in operation. Three different case studies are discussed: laser welding of dissimilar aluminium (Al) copper (Cu) connections used in electric vehicle battery manufacturing, Direct Energy Deposition with Laser Beam (DED-LB), and Laser Powder Bed Fusion (PBF-LB) with a hot isostatic press (HIP) post-processing step. Among common analysis techniques, including metallography, microscopy, tensile testing, electrical resistance, and hardness measurements, in case study 1, high-temperature confocal laser-scanning microscopy (HT-cLSM) is used to observe in situ changes in the characteristic microstructure of Al-Cu joints. In case study 2, a digital twin approach to find and mitigate anomalies in a DED-LB process shows how defect control in an AM process can be realized. Finally, in case study 3, a pore tracing analysis through X-ray CT scanning before and after the HIPing process of AlSi10Mg cylinders manufactured with PBF-LB/w shows that regardless of the initial shape, all pores tend to shrink in size and become irregularly shaped. In summary, this work provides valuable insights into various strategies for optimization of manufacturing processes and design of more robust processes, materials, and structures through defect mitigation.