Defects in Metal Additive Manufacturing Processes

Additive manufacturing of metallic components – Process, structure and properties

DebRoy, T., Wei, H. L., Zuback, J. S., Mukherjee, T., Elmer, J. W., Milewski, J. O., Beese, A. M., Wilson-Heid, A., De, A., & Zhang, W. (2018) · Progress in Materials Science · doi:10.1016/j.pmatsci.2017.10.001 · Cited by 8,805

Laser powder-bed fusion additive manufacturing: Physics of complex melt flow and formation mechanisms of pores, spatter, and denudation zones

Khairallah, S. A., Anderson, A. T., Rubenchik, A., & King, W. E. (2016) · Acta Materialia · doi:10.1016/j.actamat.2016.02.014 · Cited by 2,766

The metallurgy and processing science of metal additive manufacturing

Sames, W. J., List, F. A., Pannala, S., Dehoff, R. R., & Babu, S. S. (2016) · International Materials Reviews · doi:10.1080/09506608.2015.1116649 · Cited by 2,529

Review of in-situ process monitoring and in-situ metrology for metal additive manufacturing

Everton, S. K., Hirsch, M., Stravroulakis, P., Leach, R. K., & Clare, A. T. (2016) · Materials & Design · doi:10.1016/j.matdes.2016.01.099 · Cited by 1,469

As-Fabricated and Heat-Treated Microstructures of the Ti-6Al-4V Alloy Processed by Selective Laser Melting

Vilaro, T., Colin, C., & Bartout, J. D. (2011) · Metallurgical and Materials Transactions A · doi:10.1007/s11661-011-0731-y · Cited by 1,283

Sintering Crystalline Solids. I. Intermediate and Final State Diffusion Models

COBLE, R. L. (1961) · Journal of Applied Physics · doi:10.1063/1.1736107 · Cited by 1,152

Analysis of defect generation in Ti–6Al–4V parts made using powder bed fusion additive manufacturing processes

Gong, H., Rafi, K., Gu, H., Starr, T., & Stucker, B. (2014) · Additive Manufacturing · doi:10.1016/j.addma.2014.08.002 · Cited by 1,038

Fundamental aspects of hot isostatic pressing: An overview

Atkinson, H. V., & Davies, S. (2000) · Metallurgical and Materials Transactions A · doi:10.1007/s11661-000-0078-2 · Cited by 784

Real-time monitoring of laser powder bed fusion process using high-speed X-ray imaging and diffraction

Zhao, C., Fezzaa, K., Cunningham, R. W., Wen, H., De Carlo, F., Chen, L., Rollett, A. D., & Sun, T. (2017) · Scientific Reports · doi:10.1038/s41598-017-03761-2 · Cited by 758

Welding Metallurgy and Weldability

Lippold, J. C. (2014) · Wiley eBooks · doi:10.1002/9781118960332 · Cited by 744

In situ quality control of the selective laser melting process using a high-speed, real-time melt pool monitoring system

Clijsters, S., Craeghs, T., Buls, S., Kempen, K., & Kruth, J.-P. (2014) · The International Journal of Advanced Manufacturing Technology · doi:10.1007/s00170-014-6214-8 · Cited by 437

Porosity Measurements and Analysis for Metal Additive Manufacturing Process Control

Slotwinski, J. A., Garboczi, E. J., & Hebenstreit, K. M. (2014) · Journal of Research of the National Institute of Standards and Technology · doi:10.6028/jres.119.019 · Cited by 408

Post Processing Methods used to Improve Surface Finish of Products which are Manufactured by Additive Manufacturing Technologies: A Review

Kumbhar, N. N., & Mulay, A. V. (2018) · Journal of The Institution of Engineers (India): Series C · doi:10.1007/s40032-016-0340-z · Cited by 375

Heat transfer and material flow during laser assisted multi-layer additive manufacturing

Manvatkar, V., De, A., & DebRoy, T. (2014) · Journal of Applied Physics · doi:10.1063/1.4896751 · Cited by 338

Sensing, modeling and control for laser-based additive manufacturing

Hu, D., & Kovacevic, R. (2003) · International Journal of Machine Tools and Manufacture · doi:10.1016/s0890-6955(02)00163-3 · Cited by 329

Progress in ceramic science

Chan, R. W. (1962) · Journal of Nuclear Materials · doi:10.1016/0022-3115(62)90077-6 · Cited by 320

Quality control of laser- and powder bed-based Additive Manufacturing (AM) technologies

Berumen, S., Bechmann, F., Lindner, S., Kruth, J.-P., & Craeghs, T. (2010) · Physics Procedia · doi:10.1016/j.phpro.2010.08.089 · Cited by 307

Origin of grain orientation during solidification of an aluminum alloy

Wei, H., Elmer, J. W., & DebRoy, T. (2016) · Acta Materialia · doi:10.1016/j.actamat.2016.05.057 · Cited by 296

Porosity regrowth during heat treatment of hot isostatically pressed additively manufactured titanium components

Tammas-Williams, S., Withers, P. J., Todd, I., & Prangnell, P. B. (2016) · Scripta Materialia · doi:10.1016/j.scriptamat.2016.05.002 · Cited by 288

In-situ monitoring of melt pool images for porosity prediction in directed energy deposition processes

Khanzadeh, M., Chowdhury, S., Tschopp, M. A., Doude, H. R., Marufuzzaman, M., & Bian, L. (2019) · IISE Transactions · doi:10.1080/24725854.2017.1417656 · Cited by 278

Fabrication of Ti-6Al-4V Scaffolds by Direct Metal Deposition

Dinda, G. P., Song, L., & Mazumder, J. (2008) · Metallurgical and Materials Transactions A · doi:10.1007/s11661-008-9634-y · Cited by 264

Additive manufacturing in the context of structural integrity

Gorelik, M. (2016) · International Journal of Fatigue · doi:10.1016/j.ijfatigue.2016.07.005 · Cited by 244

Temperature Profile and Imaging Analysis of Laser Additive Manufacturing of Stainless Steel

Islam, M. D. S., Purtonen, T., Piili, H., Salminen, A., & Nyrhilä, O. (2013) · Physics Procedia · doi:10.1016/j.phpro.2013.03.156 · Cited by 156

Investigations on the influence of composition in the development of Ni–Ti shape memory alloy using laser based additive manufacturing

Shiva, S., Palani, I. A., Mishra, S. K., Paul, C. P., & Kukreja, L. M. (2014) · Optics & Laser Technology · doi:10.1016/j.optlastec.2014.12.014 · Cited by 156

Pyrometric analysis of thermal processes in SLM technology

Pavlov, M. D., Doubenskaia, M., & Smurov, I. Y. (2010) · Physics Procedia · doi:10.1016/j.phpro.2010.08.080 · Cited by 140

Spatially resolved acoustic spectroscopy for selective laser melting

Smith, R. J., Hirsch, M., Patel, R., Li, W., Clare, A. T., & Sharples, S. D. (2016) · Journal of Materials Processing Technology · doi:10.1016/j.jmatprotec.2016.05.005 · Cited by 139

Research on molten pool temperature in the process of laser rapid forming

Tan, H., Chen, J., Xin, L., et al. (2007) · Journal of Materials Processing Technology · doi:10.1016/j.jmatprotec.2007.06.090 · Cited by 137

Optical sensor for real-time monitoring of CO_2 laser welding process

Ancona, A., Spagnolo, V., Lugarà, P. M., & Ferrara, M. (2001) · Applied Optics · doi:10.1364/ao.40.006019 · Cited by 120

Intra-layer closed-loop control of build plan during directed energy additive manufacturing of Ti–6Al–4V

Nassar, A. R., Keist, J. S., Reutzel, E. W., et al. (2015) · Additive manufacturing · doi:10.1016/j.addma.2015.03.005 · Cited by 102

Online study of cracks during laser cladding process based on acoustic emission technique and finite element analysis

Wang, F., Mao, H., Zhang, D., et al. (2008) · Applied Surface Science · doi:10.1016/j.apsusc.2008.09.039 · Cited by 97

Vision-based defect detection in laser metal deposition process

Barua, S., Liou, F., Newkirk, J. W., et al. (2014) · Rapid Prototyping Journal · doi:10.1108/rpj-04-2012-0036 · Cited by 87

Real Time Cr Measurement Using Optical Emission Spectroscopy During Direct Metal Deposition Process

Song, L., & Mazumder, J. (2011) · IEEE Sensors Journal · doi:10.1109/jsen.2011.2162316 · Cited by 83

Infrared thermography for laser-based powder bed fusion additive manufacturing processes

Moylan, S. P., Whitenton, E. P., Lane, B. M., & Slotwinski, J. A. (2014) · AIP conference proceedings · doi:10.1063/1.4864956 · Cited by 80

Ultrasonic online monitoring of additive manufacturing processes based on selective laser melting

Rieder, H., Dillhöfer, A., Spies, M., Bamberg, J., & Hess, T. (2015) · AIP conference proceedings · doi:10.1063/1.4914609 · Cited by 77

Powder-based additive manufacturing - a review of types of defects, generation mechanisms, detection, property evaluation and metrology

Collins, P. C., Bond, L. J., Taheri, H., Bigelow, T. A., Shoaib, M. R. B. M., & Koester, L. W. (2017) · International Journal of Additive and Subtractive Materials Manufacturing · doi:10.1504/ijasmm.2017.10009247 · Cited by 74

Sensing Defects during Directed-Energy Additive Manufacturing of Metal Parts using Optical Emissions Spectroscopy

Nassar, A. R., Spurgeon, T. J., & Reutzel, E. W. (2014) · Texas Digital Library (University of Texas) · doi:10.26153/tsw/15684 · Cited by 50

Direct laser deposition process within spectrographic analysis in situ

Bartkowiak, K. (2010) · Physics Procedia · doi:10.1016/j.phpro.2010.08.090 · Cited by 39

Diffusion of Degradation Products in Ceramic Moldings during Pyrolysis: Effect of Geometry

Matar, S. A., Edirisinghe, M. J., Evans, J., & Twizell, E. H. (1996) · Journal of the American Ceramic Society · doi:10.1111/j.1151-2916.1996.tb07938.x · Cited by 39

Laser ultrasonic inspection of laser cladded 316LSS and TI-6-4

Klein, M. B., & Sears, J. (2004) · International Congress on Applications of Lasers & Electro-Optics (ICALEO) · doi:10.2351/1.5060183 · Cited by 32

Thermal Modeling and Experimental Validation in the LENS™ Process

Wang, L., Felicelli, S. D., & Craig, J. E. (2007) · doi:10.26153/tsw/7197 · Cited by 16

Multi-scale defects in powder-based additively manufactured metals and alloys

Fu, J., Li, H., Song, X., & Fu, M. W. (2022) · Journal of Materials Science & Technology · doi:10.1016/j.jmst.2022.02.015 · Cited by 391

Control of grain structure, phases, and defects in additive manufacturing of high-performance metallic components

Mukherjee, T., Elmer, J. W., Wei, H. L., Lienert, T. J., Zhang, W., Kou, S., & DebRoy, T. (2023) · Progress in Materials Science · doi:10.1016/j.pmatsci.2023.101153 · Cited by 267

End-to-end prediction and design of additively manufacturable alloys using a generative AlloyGPT model

Ni, B., Glaser, B., & Taheri-Mousavi, S. M. (2025) · npj Computational Materials · doi:10.1038/s41524-025-01768-2 · Cited by 23