Tootfinder

Airborne acoustic emission enables sub-scanline keyhole porosity quantification and effective process characterization for metallic laser powder bed fusion
Haolin Liu, David Guirguis, Xuzhe Zeng, Logan Maurer, Vigknesh Rajan, Niloofar Sanaei, Chi-Ta Yang, Jack L. Beuth, Anthony D. Rollett, Levent Burak Kara
https://arxiv.org/abs/2508.13492…

Airborne acoustic emission enables sub-scanline keyhole porosity quantification and effective process characterization for metallic laser powder bed fusion
Keyhole-induced (KH) porosity, which arises from unstable vapor cavity dynamics under excessive laser energy input, remains a significant challenge in laser powder bed fusion (LPBF). This study presents an integrated experimental and data-driven framework using airborne acoustic emission (AE) to achieve high-resolution quantification of KH porosity. Experiments conducted on an LPBF system involved in situ acquisition of airborne AE and ex situ porosity imaging via X-ray computed tomography (XCT…