Static and dynamic open loop control of selective laser flash sintering conducted with direct current electric fields

Abstract Selective laser flash sintering utilizes a scanning laser as a heat source to locally initiate flash sintering in the regions scanned by the laser. A key challenge towards utilizing this process for additive manufacturing (AM) is the induced electrical current that arises during flash sintering. With traditional scan patterns conducted with static electric fields, electrical and thermal runaway and associated thermal shock cracking occur. In this study, several open‐loop control strategies with static and dynamic applied electric fields were utilized to control peak currents. These strategies were shown to be effective in reducing peak currents to below 1.0 µA and reducing the severity of, but not completely eliminating cracking. Alternative strategies are suggested that could lead to complete elimination of cracks.