LAUSR

Laser powder bed fusion (LPBF) can produce high‐value metallic components for many industries; however, its adoption for safety‐critical applications is hampered by the presence of imperfections. The interdependency between imperfections and processing parameters remains unclear. Here, the evolution of porosity and humps during LPBF using X‐ray and electron imaging, and a high‐fidelity multiphase process simulation, is quantified. The pore and keyhole formation mechanisms are driven by the mixing of high temperatures and high metal vapor concentrations in the keyhole is revealed. The irregular pores are formed via keyhole collapse, pore coalescence, and then pore entrapment by the solidification front. The mixing of the fast‐moving vapor plume and molten pool induces a Kelvin–Helmholtz instability at the melt track surface, forming humps. X‐ray imaging and a high‐fidelity model are used to quantify the pore evolution kinetics, pore size distribution, waviness, surface roughness, and melt volume under single layer conditions. This work provides insights on key criteria that govern the formation of imperfections in LPBF and suggest ways to improve process reliability.