Correlative Beam Path and Pore Defect Space Analysis for Modulated Powder Bed Laser Fusion Process

There are ongoing challenges in achieving full density metal parts via Laser Powder Bed fusion (LPBF). Numerous of studies have shown that the part density depends on the process parameters, the powder characteristics and the process environment conditions. The scan strategy and the interactions of scan paths at discontinuities such as borders, create regions with high probability of pore occurrence. In this work, the complex relation between the defects and the toolpath at border discontinuities is investigated for a print recipe which gives >99.95% solid fraction in the core of the part. Samples are scanned by X-ray Computed Tomography (CT). The pore space was analyzed to extract the pore frequency, size, shape and location with respect to the scan path, border and contour strategies.