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Metal additive manufacturing (AM) by laser powder bed fusion (L-PBF) builds upon fundamentals established in the field of laser welding which include the influence of gas and plume dynamics on weld depth and quality. L-PBF demands a thorough investigation of the complex thermophysical phenomena that occur where the laser interacts with the metal powder bed. In particular, melt pool turbulence and evaporation are influenced by the ambient gas chemistry and pressure. This paper presents the design and validation of high pressure laser melting (HPLM) testbed; this accommodates bare metal plate samples as well as manually-coated single powder layers, and operates at up to 300 psig. The open architecture of this testbed allows for full control of all relevant laser parameters in addition to ambient gas pressure and gas flow over the build area. Representative melt tracks and rasters on bare plate and powder are examined in order to validate system performance, and preliminary analysis concludes that pressure has a significant impact on melt pool aspect ratio. The HPLM system thus enables careful study pressure effects on processing of common L-PBF materials, and can be applied in the future to materials that are challenging to process under ambient pressure, such as those with high vapor pressures., Comment: 25 pages, 16 figures, submitted to Additive Manufacturing

Among the many additive manufacturing (AM) processes for metallic materials, selective laser melting (SLM) is arguably the most versatile in terms of its potential to realize complex geometries along with tailored microstructure. However, the complexity of the SLM process, and the need for predictive relation of powder and process parameters to the part properties, demands further development of computational and experimental methods. This review addresses the fundamental physical phenomena of SLM, with a special emphasis on the associated thermal behavior. Simulation and experimental methods are discussed according to three primary categories. First, macroscopic approaches aim to answer questions at the component level and consider for example the determination of residual stresses or dimensional distortion effects prevalent in SLM. Second, mesoscopic approaches focus on the detection of defects such as excessive surface roughness, residual porosity or inclusions that occur at the mesoscopic length scale of individual powder particles. Third, microscopic approaches investigate the metallurgical microstructure evolution resulting from the high temperature gradients and extreme heating and cooling rates induced by the SLM process. Consideration of physical phenomena on all of these three length scales is mandatory to establish the understanding needed to realize high part quality in many applications, and to fully exploit the potential of SLM and related metal AM processes.

An approach for eliminating unnecessary portions of a volume when producing a direct volume rendering is described. This reduction in volume size sacrifices some image quality in the interest of rendering speed. Since volume visualization is often used as an exploratory visualization technique, it is important to reduce rendering times, so the user can effectively explore the volume. The methods presented can speed up rendering by factors of 2 to 3 with minor image degradation. A family of decimation algorithms to reduce the number of primitives in the volume without altering the volume's grid in any way is introduced. This allows the decimation to be computed rapidly, making it easier to change decimation levels on the fly. Further, because very little extra space is required, this method is suitable for the very large volumes that are becoming common. The method is also grid-independent, so it is suitable for multiple overlapping curvilinear and unstructured, as well as regular, grids. The decimation process can proceed automatically, or can be guided by the user so that important regions of the volume are decimated less than unimportant regions. A formal error measure is described based on a three-dimensional analog of the Radon transform. Decimation methods are evaluated based on this metric and on direct comparison with reference images.

A general volume rendering technique is described that efficiently produces images of excellent quality from data defined over irregular grids having a wide variety of formats. Rendering is done in software, eliminating the need for special graphics hardware, as well as any artifacts associated with graphics hardware. Images of volumes with about one million cells can be produced in one to several minutes on a workstation with a 150 MHz processor. A significant advantage of this method for applications such as computational fluid dynamics is that it can process multiple intersecting grids. Such grids present problems for most current volume rendering techniques. Also, the wide range of cell sizes (by a factor of 10,000 or more), which is typical of such applications, does not present difficulties, as it does for many techniques. A spatial hierarchical organization makes it possible to access data from a restricted region efficiently. The tree has greater depth in regions of greater detail, determined by the number of cells in the region. It also makes it possible to render useful 'preview' images very quickly (about one second for one-million-cell grids) by displaying each region associated with a tree node as one cell. Previews show enough detail to navigate effectively in very large data sets. The algorithmic techniques include use of a kappa-d tree, with prefix-order partitioning of triangles, to reduce the number of primitives that must be processed for one rendering, coarse-grain parallelism for a shared-memory MIMD architecture, a new perspective transformation that achieves greater numerical accuracy, and a scanline algorithm with depth sorting and a new clipping technique.