Laser powder bed fusion spatters of Zr-Cu-Al-Nb metallic glass

• Published in: Journal of alloys and compounds Vol. 976; p. 173073
• Main Authors: Pauzon, Camille, Daudin, Rémi, Robaut, Florence, Berthomé, Grégory, Blandin, Jean-Jacques
• Format: Journal Article
• Language: English
• Published: Elsevier B.V 05.03.2024; Elsevier
• Subjects: Bulk metallic glasses; Chemical and Process Engineering; Crystallisation; Engineering Sciences; Lack-of-fusion defect; Laser powder bed fusion; Materials; Spatters; Spatters; Laser powder bed fusion; Crystallisation; Lack-of-fusion defect; Bulk metallic glasses
• ISSN: 0925-8388; 1873-4669
• DOI: 10.1016/j.jallcom.2023.173073

Understanding the morphology, composition and structural changes experienced by metallic glass powder particles upon laser powder bed fusion (LPBF) is the first step towards evaluating the impact of spatter generation on part quality and on feedstock degradation. This study presents the characterization of Zr-Cu-Al-Nb spatter particles by means of scanning and transmission electron microscopy with automated crystallographic orientation mapping and energy dispersive spectroscopy, and X-ray photoelectron spectroscopy. The powder exposed to the LPBF environment exhibits an average surface composition similar to the original feedstock, but with a rougher morphology. The typical spatter encountered in the remaining lack-of-fusion is a vapour-entrained particle, which probably underwent partial melting leading to the formation of α-Zr(O) dendrites, and “big-cube” Cu2Zr4O nanocrystals in its heat affected zone. In the present work, spatter characteristics are discussed considering glass properties and their connection to lack-of-fusion defects is addressed. [Display omitted] •Spatter properties of Zr-Cu-Al-Nb metallic glass formed upon LPBF are investigated.•Typical spatters are partially crystallised entrained particles.•TEM with Automated Crystallographic Orientation Mapping reveal the crystals nature.•α-Zr(O) dendrites alongside Cu2Zr4O “big-cube” nanocrystals are formed.•This is determinant to understand relationship to the LPBF material properties.