# Understanding and Controlling Powder Dynamics for Spatter-Free Pulsed-Mode Laser Powder Bed Fusion

> **NSF 01002526DB NSF RESEARCH & RELATED ACTIVIT** · Arizona State University (AZ) · $400,000

## Abstract

Laser powder bed fusion (LPBF) is a metal additive manufacturing process that uses a focused high-energy laser to selectively melt metal powders layer by layer, enabling the production of geometrically complex parts for aerospace, biomedical, and other industries. However, localized laser heating creates a highly dynamic interaction region involving powder, molten metal, vapor jet, and gas flow. These elements fluctuate rapidly during laser scanning, causing process instabilities that result in defects and compromise part quality. One major contributor to these instabilities is the stochastic ejection of powder, known as spatter. To address spatter challenges, this project will conduct a fundamental in-situ investigation of powder dynamics during the pulsed LPBF process, thus uncovering the underlying mechanisms and driving forces. Based on these insights, an analytical model will be developed that links process conditions to powder dynamics, guiding the design of a spatter-free LPBF process. This project will deepen scientific understanding of powder dynamics in pulsed LPBF. Addressing spatter issues will enhance part quality and consistency, benefiting critical sectors such as aerospace, biomedical, and defense, thereby supporting national economy, health, and security. The project includes rich educational and outreach activities to introduce K-12, undergraduate, and graduate students to additive manufacturing and the use of in-situ monitoring tools to solve real-world cha

## Key facts

- **NSF award ID:** 2523480
- **Awardee organization:** Arizona State University (AZ)
- **SAM.gov UEI:** NTLHJXM55KZ6
- **PI:** Minglei Qu
- **Primary program:** 01002526DB NSF RESEARCH & RELATED ACTIVIT
- **All programs:** CONTROL SYSTEMS, Dynamical systems, CONTROL SYSTEMS, Complex Systems
- **Estimated total:** $400,000
- **Funds obligated:** $400,000
- **Transaction type:** Standard Grant
- **Period:** 09/01/2025 → 08/31/2028

## Primary source

NSF Award Search: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2523480

## Citation

> US National Science Foundation, Award 2523480, Understanding and Controlling Powder Dynamics for Spatter-Free Pulsed-Mode Laser Powder Bed Fusion. Retrieved via AI Analytics 2026-06-08 from https://api.ai-analytics.org/grant/nsf/2523480. Licensed CC0.

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