Physical Aspects of Process Control in Selective Laser Sintering of Metals

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Abstract
Direct selective laser sintering (SLS) is a layered manufacturing technique that can produce fully dense, functional components in high performance metals. In this review paper, a first step is taken towards identifying and understanding some of the important physical mechanisms in direct SLS. This study not only provides an insight into phenomena observed during direct SLS processing of a variety of metallic materials but also helps in selecting those materials that are most amenable to direct SLS processing. The physical mechanisms discussed include oxidation, non‐equilibrium wetting, epitaxial solidification, metal vaporization, and oxide purification. Understanding these mechanisms is crucial for the design of direct SLS machines, process development, and process control.