Macro-pore free sub-surface PBF-LB/M components through laser polishing

Despite notable improvements in the laser-based powder bed fusion of metals (PBF-LB/M) in recent years, residual porosity is still an issue. Near surface pores can affect the functional properties of PBF components, such as their fatigue life, yield strength, or corrosion behavior. To help address the challenge, this work shows that laser polishing decreases the surface roughness while also creating a highly dense sub-surface region of PBF parts with only microscale pores remaining.