Accurate Detection and Analysis of Pore Defects in Laser Powder Bed Fusion WE43 Magnesium Alloys

To explore the size, morphology, and distribution patterns of internal pore defects in WE43 magnesium alloy formed by laser powder bed fusion (LPBF), as well as their impact on its mechanical properties, computer tomography (CT), metallographic microscopy, and scanning electron microscopy were used to observe the material’s microstructure and the morphology of tensile test fractures. The study revealed that a large number of randomly distributed non-circular pore defects exist internally in the LPBF-formed WE43 magnesium alloy, with a defect volume fraction of 0.16%. Approximately 80% of the defects had equivalent diameters concentrated in the range of 10∼40 $\mathsf{\mu }$m, and 56.2% of the defects had sphericity values between 0.65∼0.7 $\mathsf{\mu }$m, with the maximum defect equivalent diameter being 122 $\mathsf{\mu }$m. There were a few spherical pores around 20 $\mathsf{\mu }$m in diameter in the specimens, and unfused powder particles were found in pore defects near the edges of the parts. Under the test conditions, the fusion pool structure of LPBF-formed WE43 magnesium alloy resembled a semi-elliptical shape with a height of around 66 $\mathsf{\mu }$m, capable of fusion three layers of powder material in a single pass. Columnar grains formed at the edge of individual fusion pools, while the central area exhibited equiaxed grains. The “scale-like pattern” formed by overlapping fusion pool structures resulted in the microstructure of LPBF-formed WE43 magnesium alloy mainly consisting of fine equiaxed grains with a size of 2.5 $\mathsf{\mu }$m and columnar grains distributed in a band-like manner.