Quantitative characterization of porosity in stainless steel LENS powders and deposits

Laser Engineered Net Shaping (LENS) utilizes a laser beam to melt fine powders to produce three-dimensional engineering structures line by line and layer by layer. When building these structures, defects including lack-of-fusion (LOF) at interlayer boundaries and intralayer porosity are sometimes observed. LOF defects can be minimized by adjusting processing parameters, but the sources of intralayer porosity are less apparent. In this paper, the amount and size distributions of 17-4PH and 304L powders and pores within the powder were characterized in parallel with the intralayer porosity in LENS deposits fabricated from the same materials. Intralayer porosity increased with increased powder porosity; but was not well correlated with deposition parameters. The results demonstrate the importance of careful characterization and specification of starting powders on the quality of the final LENS deposits.