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Related Concept Videos

Imperfections in Crystal Structure: Non-Stoichiometric Defects01:29

Imperfections in Crystal Structure: Non-Stoichiometric Defects

Non-stoichiometric defects refer to a type of defect in the crystal structure of a compound where the ratio of its constituent elements deviates from the ideal stoichiometric ratio. There are two main types of non-stoichiometric defects: metal excess defects and metal deficiency defects.Metal excess defects occur when there is a slight surplus of metal ions than what is required by the stoichiometric ratio of the compound. For example, heating a sodium chloride crystal in sodium vapor results...

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Related Experiment Video

Updated: May 17, 2026

Multi-material Ceramic-Based Components – Additive Manufacturing of Black-and-white Zirconia Components by Thermoplastic 3D-Printing (CerAM - T3DP)
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Multi-material Ceramic-Based Components – Additive Manufacturing of Black-and-white Zirconia Components by Thermoplastic 3D-Printing (CerAM - T3DP)

Published on: January 7, 2019

Mixing-Driven Defects and Composition Evolution in Multi-Material Metal Additive Manufacturing.

Zhilang Zhang1, Steve Gaudez2, Mario Togni3

  • 1School of Advanced Manufacturing and Robotics, Peking University, Beijing, China.

Advanced Science (Weinheim, Baden-Wurttemberg, Germany)
|May 15, 2026
PubMed
Summary
This summary is machine-generated.

Multi-material laser powder bed fusion (LPBF) creates complex parts, but defects arise from melt pool instabilities. This study reveals how material mixing drives keyhole instability and pore formation, enabling better process control.

Keywords:
additive manufacturingdefect formationhigh‐fidelity simulationin situ X‐ray imaginglaser powder bed fusionmulti‐material

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Area of Science:

  • Materials Science
  • Additive Manufacturing
  • Physics

Background:

  • Multi-material laser powder bed fusion (LPBF) offers advanced component fabrication with tailored compositions.
  • Process design is hindered by limited understanding of melt pool dynamics, mixing, and defect generation.

Purpose of the Study:

  • To investigate the real-time interplay between material mixing, keyhole instability, and pore formation in multi-material LPBF.
  • To establish a validated mechanistic framework for optimizing multi-material LPBF processes.

Main Methods:

  • Operando synchrotron X-ray radiography was combined with high-fidelity multi-material multiphysics modeling.
  • Transient composition fields and melt pool transport were quantitatively mapped.

Main Results:

  • Material mixing fundamentally alters keyhole stability, causing composition-driven transitions and collapse events that lead to large pores.
  • Microscale gas entrapment during convection of dissimilar materials generates fine pores.
  • Local alloying gradients influence defect formation and melt pool behavior.

Conclusions:

  • A mechanistic framework for multi-material LPBF was established.
  • Quantitative insights enable process optimization for defect control and compositionally graded manufacturing.