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Strategies to Mitigate Interlayer Porosity in the Laser-Directed Energy Deposition Process.

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Title: Strategies to Mitigate Interlayer Porosity in the Laser-Directed Energy Deposition Process.
Authors: Jha, Arkajyoti1 me20resch11001@iith.ac.in, Ramji, M.1 ramji_mano@mae.iith.ac.in, Torris, Arun2 t.arun.ncl@csir.res.in, Gopinath, Muvvala1 mgopinath@mae.iith.ac.in
Source: Journal of Manufacturing Science & Engineering. Jun2026, Vol. 148 Issue 6, p148-148. 1p.
Subjects: Porosity, Laser deposition, Manufacturing defects, Surface finishing, Grain refinement
Abstract: Laser-directed energy deposition (L-DED) offers unique advantages for fabricating large-scale metallic components and repairing high-value parts. However, recurring interlayer porosity, particularly while depositing targeted geometry and dimensions, remains a major limitation affecting structural integrity. In this study, systematic deposition strategies were developed to mitigate interlayer porosity by controlling track overlap and optimizing energy apportionment, the two aspects that have not been reported together in previous L-DED studies. Experimental analysis showed that increasing the percentage overlap from 30% to 40% significantly reduced porosity, whereas defining the overlap based on the full width at half maximum (FWHM) provided a more geometry-representative approach. A 30% FWHM overlap was found to be most effective in disrupting periodic porosity recurrence. Additionally, introducing skewed track alignment minimized valley-to-valley overlap across layers, further reducing defect formation. Complementary to geometric strategies, interlayer laser polishing with circular and line beams facilitated pore closure while refining the interlayer microstructure. A key novelty of this work lies in coupling overlap optimization with energy apportionment between powder and substrate, achieved by adjusting the stand-off distance (SoD), which is quantified by a unique experimental approach. This enhanced molten pool flow and ensured improved remelting of the previously deposited layer, which, when combined with a 30% FWHM overlap, effectively eliminated visible interlayer porosity, validated by micro-computed tomography analysis. The integrated approach of optimized overlap, energy apportionment, and interlayer polishing enabled defect-free fabrication of straight walls as well as complex turbine blade profiles, while simultaneously enhancing strength and ductility. [ABSTRACT FROM AUTHOR]
Copyright of Journal of Manufacturing Science & Engineering is the property of American Society of Mechanical Engineers and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
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DbLabel: Engineering Source
An: 194389213
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
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  Data: Strategies to Mitigate Interlayer Porosity in the Laser-Directed Energy Deposition Process.
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  Data: <searchLink fieldCode="AR" term="%22Jha%2C+Arkajyoti%22">Jha, Arkajyoti</searchLink><relatesTo>1</relatesTo><i> me20resch11001@iith.ac.in</i><br /><searchLink fieldCode="AR" term="%22Ramji%2C+M%2E%22">Ramji, M.</searchLink><relatesTo>1</relatesTo><i> ramji_mano@mae.iith.ac.in</i><br /><searchLink fieldCode="AR" term="%22Torris%2C+Arun%22">Torris, Arun</searchLink><relatesTo>2</relatesTo><i> t.arun.ncl@csir.res.in</i><br /><searchLink fieldCode="AR" term="%22Gopinath%2C+Muvvala%22">Gopinath, Muvvala</searchLink><relatesTo>1</relatesTo><i> mgopinath@mae.iith.ac.in</i>
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  Data: <searchLink fieldCode="JN" term="%22Journal+of+Manufacturing+Science+%26+Engineering%22">Journal of Manufacturing Science & Engineering</searchLink>. Jun2026, Vol. 148 Issue 6, p148-148. 1p.
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  Data: <searchLink fieldCode="DE" term="%22Porosity%22">Porosity</searchLink><br /><searchLink fieldCode="DE" term="%22Laser+deposition%22">Laser deposition</searchLink><br /><searchLink fieldCode="DE" term="%22Manufacturing+defects%22">Manufacturing defects</searchLink><br /><searchLink fieldCode="DE" term="%22Surface+finishing%22">Surface finishing</searchLink><br /><searchLink fieldCode="DE" term="%22Grain+refinement%22">Grain refinement</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: Laser-directed energy deposition (L-DED) offers unique advantages for fabricating large-scale metallic components and repairing high-value parts. However, recurring interlayer porosity, particularly while depositing targeted geometry and dimensions, remains a major limitation affecting structural integrity. In this study, systematic deposition strategies were developed to mitigate interlayer porosity by controlling track overlap and optimizing energy apportionment, the two aspects that have not been reported together in previous L-DED studies. Experimental analysis showed that increasing the percentage overlap from 30% to 40% significantly reduced porosity, whereas defining the overlap based on the full width at half maximum (FWHM) provided a more geometry-representative approach. A 30% FWHM overlap was found to be most effective in disrupting periodic porosity recurrence. Additionally, introducing skewed track alignment minimized valley-to-valley overlap across layers, further reducing defect formation. Complementary to geometric strategies, interlayer laser polishing with circular and line beams facilitated pore closure while refining the interlayer microstructure. A key novelty of this work lies in coupling overlap optimization with energy apportionment between powder and substrate, achieved by adjusting the stand-off distance (SoD), which is quantified by a unique experimental approach. This enhanced molten pool flow and ensured improved remelting of the previously deposited layer, which, when combined with a 30% FWHM overlap, effectively eliminated visible interlayer porosity, validated by micro-computed tomography analysis. The integrated approach of optimized overlap, energy apportionment, and interlayer polishing enabled defect-free fabrication of straight walls as well as complex turbine blade profiles, while simultaneously enhancing strength and ductility. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of Journal of Manufacturing Science & Engineering is the property of American Society of Mechanical Engineers and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1115/1.4071350
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        Text: English
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        StartPage: 148
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      – SubjectFull: Porosity
        Type: general
      – SubjectFull: Laser deposition
        Type: general
      – SubjectFull: Manufacturing defects
        Type: general
      – SubjectFull: Surface finishing
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      – SubjectFull: Grain refinement
        Type: general
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      – TitleFull: Strategies to Mitigate Interlayer Porosity in the Laser-Directed Energy Deposition Process.
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            NameFull: Jha, Arkajyoti
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            NameFull: Ramji, M.
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            NameFull: Torris, Arun
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            NameFull: Gopinath, Muvvala
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            – D: 01
              M: 06
              Text: Jun2026
              Type: published
              Y: 2026
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