Defect formation mechanisms in selective laser melting: a review
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Abstract Defect formation is a common problem in selective laser melting (SLM). This paper provides a review of defect formation mechanisms in SLM. It summarizes the recent research outcomes on defect findings and classification, analyzes formation mechanisms of the common defects, such as porosities, incomplete fusion holes, and cracks. The paper discusses the effect of the process parameters on defect formation and the impact of defect formation on the mechanical properties of a fabricated part. Based on the discussion, the paper proposes strategies for defect suppression and control in SLM.
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Powder-based processes are prone to issues of porosity, lack-of-fusion, balling, and cracks, while geometry deviation, shape shrinkage, surface imperfections, layer misalignment, and adhesion issues are the main concerns in the FFF processes.
“Powder-based processes are prone to issues of porosity, lackof-fusion, balling, and cracks [428,430,431], while geometry deviation, shape shrinkage, surface imperfections, layer misalignment, and adhesion issues [432-435] are the main concerns in the FFF processes.”
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Sorted by citations
A comprehensive review of lunar-based manufacturing and construction
Azami, M., Kazemi, Z., Moazen, S., Dubé, M., Potvin, M.-J., & Skonieczny, K. (2024) · Progress in Aerospace Sciences · doi:10.1016/j.paerosci.2024.101045 · Cited by 57 · see citing works
- Authors
- Zhang, B., Li, Y., & Bai, Q.
- Affiliations
- University of Connecticut (US)
- Dalian University of Technology (CN)
- Corresponding author
- Zhang, Bi
- Venue
- Chinese Journal of Mechanical Engineering
- Publisher
- Elsevier BV
- Published
- 2017-04-21
- Volume
- 30
- Issue
- 3
- Pages
- 515-527
- ISSN
- 1000-9345 (ISSN-L)
- 2192-8258
- OpenAlex
- W2607588067
- Cited by
- 924
- References
- 70
- Citations by year
- 2026: 82 · 2025: 116 · 2024: 131 · 2023: 149 · 2022: 145 · 2021: 126 · 2020: 96 · 2019: 52 · 2018: 24 · 2017: 3
- FWCI
- 37.19
- Type
- journal article
- Language
- en
- Update notices
- erratum (2017-08-03)
- Open access
- hybrid
- doi.org
- Locations
- Chinese Journal of Mechanical Engineering (publishedVersion, cc-by)
- DOAJ (DOAJ: Directory of Open Access Journals) (submittedVersion, cc-by-sa)
- Funders
- National Natural Science Foundation of China (51605077)
- Topics
- Physical Sciences › Engineering › Mechanical Engineering › Additive Manufacturing Materials and Processes
- Physical Sciences › Engineering › Automotive Engineering › Additive Manufacturing and 3D Printing Technologies
- Physical Sciences › Engineering › Mechanical Engineering › Welding Techniques and Residual Stresses
- Keywords
- laser powder bed fusion, additive manufacturing defects, porosity, incomplete fusion, cracks, defect formation mechanism, process parameters, mechanical properties, defect reduction
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