Electromagnetic Churning of Laser Melt-Pool in Metal 3D Printing

Manufacturing flaws and microstructure irregularities pose challenges for the widespread adoption of metal additive manufacturing (MAM) in the US Army. These issues stem from the influence of melt-pool dynamics on the properties of 3D-printed metal parts, which are highly dependent on multiple process parameters. This paper investigates the potential of using electromagnetic fields (EM) to control the melt-pool dynamics in MAM, aiming to eliminate flaws and irregularities. A novel technique is proposed, involving a coil and strategically positioned permanent magnets to actively churn the melt pool. Initial validation of this approach was conducted using COMSOL Multiphysics® through simulation modeling, with ongoing efforts for experimental verification. The findings indicate promising opportunities for enhancing the consistency of 3D printed parts.