Elucidation of dross formation in laser powder bed fusion at down-facing surfaces: phenomenon-oriented multiphysics simulation and experimental validation

Dross formation is a phenomenon that is observed while printing metallic components using Laser Powder Bed Fusion (L-PBF) and occurring primarily at down-facing surfaces that are unsupported and suffer inadequate heat removal. Naturally, dross formation causes dimensional inaccuracy, high surface roughness and also adversely affects the mechanical properties of printed components. Through simulation and experimentation, this study fundamentally elucidates the driving phenomenon behind dross formation. The simulation results, in terms of the degree of generated dross domain, well agree with the ones observed in the printed samples and the behaviour of the melt pool while moving from bulk material to the powder domain is clearly depicted in this study. The simulations show that due to the low thermal conductivity of loose powder and the inability to conduct heat away, the quasi steady state melt pool collapses while entering the powder domain and transitions to a keyhole-like melt mode which causes a pronounced drilling effect. This causes excessive melting known as dross that is seen both in the simulation and the experimental parts. This work also shows through simulation and experimentation the reasoning behind the production of larger and smaller dross domains while printing with high and low laser energy densities respectively. Additionally, through SEM imagery this study also explains the observed deep internal grooves and near-surface porosity that are present within this dross domain which can further affect mechanical properties such as density, fatigue strength etc