Spatter detection and tracking in high-speed video observations of laser powder bed fusion

Abstract

Purpose

In laser powder bed fusion (L-PBF) additive manufacturing, spatter particles are ejected from the melt pool and can be detrimental to material performance and powder recycling. Quantifying spatter generation with respect to processing conditions is a step toward mitigating spatter and better understanding the phenomenon. This paper reveals process insights of spatter phenomena by automatically annotating spatter particles in high-speed video observations using machine learning.

Design/methodology/approach

A high-speed camera was used to observe the L-PBF process while varying laser power, laser scan speed and scan strategy on a constant geometry on an EOSM290 using Ti-6Al-4V powder. Two separate convolutional neural networks were trained to segment and track spatter particles in captured high-speed videos for spatter characterization.

Findings

Spatter generation and ejection angle significantly differ between keyhole and conduction mode melting. High laser powers lead to large ejections at the beginning of scan lines. Slow and fast build rates produce more spatter than moderate build rates at constant energy density. Scan strategies with more scan vectors lead to more spatter. The presence of powder significantly increases the amount of spatter generated during the process.

Originality/value

With the ability to automatically annotate a large volume of high-speed video data sets with high accuracy, an experimental design of observed parameter changes reveals quantitively stark changes in spatter morphology that can aid process development to mitigate spatter occurrence and impacts on material performance.

Citation

Gobert, C., Diewald, E. and Beuth, J.L. (2025), "Spatter detection and tracking in high-speed video observations of laser powder bed fusion", Rapid Prototyping Journal, Vol. 31 No. 2, pp. 393-408. https://doi.org/10.1108/RPJ-03-2023-0108