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Abstract Keyhole-mode laser melting is an efficient method for joining or cutting large, thick components, but controlling keyhole depth and fluctuations has remained challenging. Applying an external magnetic field can control melt pool flows and indirectly influence keyhole morphology and dynamics. The induced Lorentz force, comprising Seebeck and damping components, plays a crucial role in the melt pool dynamics, depending on temperature gradient, flow rates, and magnetic field orientation and magnitude. This research investigates the effects of an external magnetic field on keyhole behavior during laser spot melting of 316 stainless steel using synchronized high-speed synchrotron X-ray and thermal imaging. Findings revealed that a longitudinal magnetic field (120 mT) increased keyhole depth but exacerbated lateral fluctuations, resulted in a 20% increase in the melt pool temperature gradient and a 27% decrease in cooling rate. Conversely, a transverse magnetic field (760 mT) reduced keyhole depth and improved porosity formation. The findings suggest that a decrease in keyhole depth correlates with a decrease in fluctuations, and vice versa. These insights enhance understanding of external magnetic fields’ impact on laser melting, with implications for improving part quality.more » « less
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Haddad, Marwan; Cohen, Mathew; Bafahm_Alamdari, Aslan; Welk, Brian; Fezzaa, Kamel; Wolff, Sarah (, Additive Manufacturing)Free, publicly-accessible full text available May 1, 2026
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Haddad, Marwan; Bafahm_Alamdari, Aslan; Vinod_Kankaria, Karan; Wang, Hui; Gould, Benjamin; Wolff, Sarah J (, Manufacturing Letters)
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