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This research investigates how substrate microstructure affects defect formation during laser powder bed fusion of aluminium alloys.

Influence of substrate microstructure on defect formation during Al alloy laser powder bed fusion

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Experiments reveal intermetallics impact defect formation in Al alloy PBF-LB, suggesting new printing strategies.

This research investigates how substrate microstructure affects defect formation during laser powder bed fusion of aluminium alloys.
Conducted single-track PBF-LB experiments using as-cast PA1 and as-rolled Al6061 substrates.
Performed microstructural analysis to evaluate track quality and defect types.
Used high-speed synchrotron X-ray imaging for detailed observations.
Identified new defect type, intermetallic-induced pores, stemming from substrate interactions.
Optimal conditions lead to very fine eutectic cells with no defects in PA1.
Defect influence decreases with build height as microstructures homogenize.

Guo et al. (2026) studied this question.

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