Relation of particle motion and process zone formation as a basis for sensing approaches within PBF-LB/M

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Laser powder bed fusion of metals (PBF-LB/M) is a promising additive manufacturing technology that allows for greater design freedom through the layerwise and selective melting of powder. However, local process deviations can affect mechanical properties, necessitating the use of sensors for detection to enhance industrial adoption. This thesis explores the correlations between spatter particle properties and microscopic process behavior, focusing on their relevance in an industrial context. A novel particle tracking velocimetry method is developed to spatially and temporally resolve individual particle trajectories. Statistical measurements of spatter are correlated with process observations, highlighting their connection to evaporation-driven mechanisms. The research investigates the applicability of these correlations for quantifying microscopic process zone characteristics and assesses their robustness against varying process conditions. Ultimately, the study demonstrates the transferability of findings from the lab to an industrially viable sensing approach, facilitated by a specialized data processing method for real-time derivation of spatter properties. This work aims to enhance the understanding and monitoring of PBF-LB/M processes, contributing to improved mechanical properties and broader industrial use.