From remelting cycles to sustained melting: Defect and microstructure in laser powder bed fusion of AA6061 with modulated laser

2026-08-06

PRE

Can Sun

Sivaji Karna

Daniel Morrall

Rimah Al Aridi

Zilong Zhang

Andrew J. Gross

Timothy Krentz

Dale Hitchcock

Lang Yuan *

DOI：10.1016/j.addma.2026.105334

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Abstract

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• Pulsed laser creates remelting-cycle vs sustained-melting regimes. • Remelting cycles reduce cracking and refine grains with weaker textures. • Sustained melting deepens pools, lowers porosity, but coarsens microstructure. • Optimal pulsing parameters achieve ∼0.3% porosity and ∼0.1% crack density. • T6 heat treatment boosts mechanical properties while preserving grain/subgrain differences.

Keywords:

Laser modulation

Defect formation

Microstructure

Precipitation

Mechanical property

From remelting cycles to sustained melting: Defect and microstructure in laser powder bed fusion of AA6061 with modulated laser

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