Experimental Study on Wire Melting Control Ability of Twin-Body Plasma Arc

The twin-body plasma arc has the decoupling control ability of heat transfer and mass transfer,which is beneficial to shape and property control in wire arc additive manufacturing.In this paper,with the wire feeding speed as a characteristic quantity,the wire melting control ability of twin-body plasma arc was studied by adjusting the current separation ratio(under the condition of a constant total current),the wire current/main current and the position of the wire in the arc axial direction.The results showed that under the premise that the total current remains unchanged(100 A),as the current separation ratio increased,the middle and minimum melting amounts increased approximately synchronously under the effect of anode effect power,the first melting mass range remained constant;the maximum melting amount increased twice as fast as the middle melting amount under the effect of the wire feeding speed,and the second melting mass range was expanded.When the wire current increased,the anode effect power and the plasma arc power were both factors causing the increase in the wire melting amount;however,when the main current increased,the plasma arc power was the only factor causing the increase in the wire melting amount.The average wire melting increment caused by the anode effect power was approximately 2.7 times that caused by the plasma arc power.The minimum melting amount was not affected by the wire-torch distance under any current separation ratio tested.When the current separation ratio increased and reached a threshold,the middle melting amount remained constant with increasing wire-torch distance.When the current separation ratio continued to increase and reached the next threshold,the maximum melting amount remained constant with the increasing wire-torch distance.The effect of the wire-torch distance on the wire melting amount reduced with the increase in the current separation ratio.Through this study,the decoupling mechanism and ability of this innovative arc heat source is more clearly.

Experimental study on reactions between alkaline basaltic melt and orthopyroxenes: constraints on the evolution of lithospheric mantle in the North China Craton

The experimental results of the reactions between an alkaline basaltic melt and mantle orthopyroxenes under high-temperature and high-pressure conditions of 1300–1400℃ and 2.0–3.0 GPa using a six-anvil apparatus are reported in this paper.The reactions are proposed to simulate the interactions between melts from the asthenospheric mantle and the lithospheric mantle.The starting melt in the experiments was made from the alkaline basalt occurring in Fuxin,Liaoning Province,and the orthopyroxenes were separated from the mantle xenoliths in Damaping,Hebei Province.The results show that clinopyroxenes were formed in all the reactions between the alkaline basaltic melt and orthopyroxenes under the studied P–T conditions.The formation of clinopyroxene in the reaction zone is mainly controlled by dissolution–crystallization,and the chemical compositions of the reacted melt are primarily infl uenced by the diff usion eff ect.Temperature is the most important parameter controlling the reactions between the melt and orthopyroxenes,which has a direct impact on the melting of orthopyroxenes and the diff usion of chemical components in the melt.Temperature also directly controls the chemical compositions of the newly formed clinopyroxenes in the reaction zone and the reacted melt.The formation of clinopyroxenes from the reactions between the alkaline basaltic melt and orthopyroxenes can result in an increase of CaO and Al_(2)O_(3) contents in the rocks containing this mineral.Therefore,the reactions between the alkaline basaltic melt from the asthenospheric mantle and orthopyroxenes from the lithospheric mantle can lead to the evolution of lithospheric mantle in the North China Craton from refractory to fertile with relatively high CaO and Al 2 O 3 contents.In addition,the reacted melts in some runs were transformed from the starting alkaline basaltic into tholeiitic after reactions,indicating that tholeiitic magma could be generated from alkaline basaltic one via reactions between the latter and orthopyroxene.

Investigation of Microstructure and Phase Composition of Chromic Oxide, AZS/Cr and High-alumina Refractories after Exposure of Basalt and Aluminaboronsilicate Glasses Melts

The microstructure and phase composition of high-alumina,chromic oxide,and AZS/Cr refractories containing 30%and 60%(by mass)Cr_(2)O_(3) after exposure to aluminaboronsilicate glasses and basalt melts depending on the type of melts and temperature have been studied.The mechanisms of refractory corrosion by the used melts and the factors contributing to the inhibition of corrosion development have been investigated by the method of petrographic analysis.On the basis of obtained results,the use of high-alumina,chromic oxide,and AZS/Cr refractories in the sections of glass furnace linings,experiencing the intensive impact of aluminaboronsilicate glasses and basalt melts,has been confirmed and scientifically substantiated.

Effects of projectile parameters on the momentum transfer and projectile melting during hypervelocity impact

The effects of projectile/target impedance matching and projectile shape on energy,momentum transfer and projectile melting during collisions are investigated by numerical simulation.By comparing the computation results with the experimental results,the correctness of the calculation and the statistical method of momentum transfer coefficient is verified.Different shapes of aluminum,copper and heavy tungsten alloy projectiles striking aluminum,basalt,and pumice target for impacts up to 10 km/s are simulated.The influence mechanism of the shape of the projectile and projectile/target density on the momentum transfer was obtained.With an increase in projectile density and length-diameter ratio,the energy transfer time between the projectile and targets is prolonged.The projectile decelerates slowly,resulting in a larger cratering depth.The energy consumed by the projectile in the excavation stage increased,resulting in lower mass-velocity of ejecta and momentum transfer coefficient.The numerical simulation results demonstrated that for different projectile/target combinations,the higher the wave impedance of the projectile,the higher the initial phase transition velocity and the smaller the mass of phase transition.The results can provide theoretical guidance for kinetic impactor design and material selection.

Interplay of laser power and pore characteristics in selective laser melting of ZK60 magnesium alloys:A study based on in-situ monitoring and image analysis

This study offers significant insights into the multi-physics phenomena of the SLM process and the subsequent porosity characteristics of ZK60 Magnesium(Mg)alloys.High-speed in-situ monitoring was employed to visualise process signals in real-time,elucidating the dynamics of melt pools and vapour plumes under varying laser power conditions specifically between 40 W and 60 W.Detailed morphological analysis was performed using Scanning-Electron Microscopy(SEM),demonstrating a critical correlation between laser power and pore formation.Lower laser power led to increased pore coverage,whereas a denser structure was observed at higher laser power.This laser power influence on porosity was further confirmed via Optical Microscopy(OM)conducted on both top and cross-sectional surfaces of the samples.An increase in laser power resulted in a decrease in pore coverage and pore size,potentially leading to a denser printed part of Mg alloy.X-ray Computed Tomography(XCT)augmented these findings by providing a 3D volumetric representation of the sample internal structure,revealing an inverse relationship between laser power and overall pore volume.Lower laser power appeared to favour the formation of interconnected pores,while a reduction in interconnected pores and an increase in isolated pores were observed at higher power.The interplay between melt pool size,vapour plume effects,and laser power was found to significantly influence the resulting porosity,indicating a need for effective management of these factors to optimise the SLM process of Mg alloys.

Stability and melting behavior of boron phosphide under high pressure

Boron phosphide(BP)has gained significant research attention due to its unique photoelectric and mechanical properties.In this work,we investigated the stability of BP under high pressure using x-ray diffraction and scanning electron microscope.The phase diagram of BP was explored in both B-rich and P-rich environments,revealing crucial insight into its behavior at 5.0 GPa.Additionally,we measured the melting curve of BP from 8.0 GPa to 15.0 GPa.Our findings indicate that the stability of BP under high pressure is improved within B-rich and P-rich environments.Furthermore,we report a remarkable observation of melting curve frustration at 10.0 GPa.This study will enhance our understanding of stability of BP under high pressure,shedding light on its potential application in semiconductor,thermal,and light-transmitting devices.

Melting geodynamics reveals a subduction origin for the Purang ophiolite,Tibet,China

The debate regarding whether the Yarlung-Zangbo ophiolite(YZO)on the south of the Qinghai-Tibet Plateau,formed in a mid-ocean ridge(MOR)or a supra-subduction zone(SSZ)setting has remained unresolved.Here we present petrological,mineralogical,and geochemical data associated with modeling melting geodynamics of the mantle peridotites from the Purang ophiolite in the western segment of the Yarlung-Zangbo Suture Zone(YZSZ)to explore its tectonic environment.The Purang lherzolites are characterized by the protogranular texture and have abyssal-peridotite-like mineral compositions,including low Cr^(#)(20-30)and TiO_(2) contents(<0.1wt%)in spinel,high Al_(2)O_(3)(2.9wt%-4.4wt%)and CaO(1.9wt%-3.7wt%)contents in orthopyroxene and LREE-depletion in clinopyroxene.Compositions of these lherzolites can be modeled by~11%dynamic melting of the DMM source with a small fraction of melt(~0.5%)entrapped within the source,a similar melting process to typical abyssal peridotites.The Purang harzburgites are characterized by the porphyroclastic texture and exhibit highly refractory mineral compositions such as high spinel Cr^(#)(40-68),low orthopyroxene Al_(2)O_(3)(<2.2wt%)and CaO(<1.1wt%)contents.Clinopyroxenes in these harzburgites are enriched in Sr(up to 6.0 ppm)and LREE[(Ce)N=0.02-0.4],but depleted in Ti(200 ppm,on average)and HREE[(Yb)N<2].Importantly,the more depleted samples tend to have higher clinopyroxene Sr and LREE contents.These observations indicate an open-system hydrous melting with a continuous influx of slab fluid at a subduction zone.The modeled results show that these harzburgites could be formed by 19%-23%hydrous melting with the supply rate of slab fluid at 0.1%-1%.The lower clinopyroxene V/Sc ratios in harzburgites than those in lherzolites suggest a high oxidation stage of the melting system of harzburgites,which is consistent with a hydrous melting environment for these harzburgites.It is therefore concluded that the Purang ophiolite has experienced a transformation of tectonic setting from MOR to SSZ.

High-strength and thermally stable TiB_(2)-modified Al-Mn-Mg-Er-Zr alloy fabricated via selective laser melting

To increase the processability and plasticity of the selective laser melting(SLM)fabricated Al-Mn-Mg-Er-Zr alloys,a novel TiB_(2)-modified Al-Mn-Mg-Er-Zr alloy with a mixture of Al-Mn-Mg-Er-Zr and nano-TiB_(2) powders was fabricated by SLM.The pro-cessability,microstructure,and mechanical properties of the alloy were systematically investigated by density measurement,microstruc-ture characterization,and mechanical properties testing.The alloys fabricated at 250 W displayed higher relative densities due to a uni-formly smooth top surface and appropriate laser energy input.The maximum relative density value of the alloy reached(99.7±0.1)%,demonstrating good processability.The alloy exhibited a duplex grain microstructure consisting of columnar regions primarily and equiaxed regions with TiB_(2),Al6Mn,and Al3Er phases distributed along the grain boundaries.After directly aging treatment at a high tem-perature of 400℃,the strength of the SLM-fabricated TiB_(2)/Al-Mn-Mg-Er-Zr alloy increased due to the precipitation of the secondary Al6Mn phases.The maximum yield strength and ultimate tensile strength of the aging alloy were measured to be(374±1)and(512±13)MPa,respectively.The SLM-fabricated TiB_(2)/Al-Mn-Mg-Er-Zr alloy demonstrates exceptional strength and thermal stability due to the synergistic effects of the inhibition of grain growth,the incorporation of TiB_(2) nanoparticles,and the precipitation of secondary Al6Mn nanoparticles.

Strength and plasticity improvement induced by strong grain refinement after Zr alloying in selective laser-melted AlSiMg1.4 alloy

In order to enhance the mechanical properties of the selective laser-melted(SLM) high-Mg content AlSiMg1.4 alloy,the Zr element was introduced.The influence of Zr alloying on the processability,microstructure,and mechanical properties of the alloy was systematically investigated through performing microstructure analysis and tensile testing.It was demonstrated that the SLM-fabricated AlSiMg1.4-Zr alloy exhibited high process stability with a relative density of over 99.5% at various process parameters.Besides,the strong grain refinement induced by the primary Al3Zr particle during the melt solidification process simultaneously enhanced both the strength and plasticity of the alloy.The values for the yield strength,ultimate tensile strength,and elongation of the SLM-fabricated AlSiMg1.4-Zr were(343±3) MPa,(485±4) MPa,and(10.2±0.2)%,respectively,demonstrating good strengthplasticity synergy in comparison to the AlSiMg1.4 and other Al-Si-based alloys fabricated by SLM.

Effects of processing parameters on fabrication defects,microstructure and mechanical properties of additive manufactured Mg–Nd–Zn–Zr alloy by selective laser melting process

Mg–3Nd–0.2Zn–0.4Zr(NZ30K,wt.%)alloy is a new kind of high-performance metallic biomaterial.The combination of the NZ30K Magnesium(Mg)alloy and selective laser melting(SLM)process seems to be an ideal solution to produce porous Mg degradable implants.However,the microstructure evolution and mechanical properties of the SLMed NZ30K Mg alloy were not yet studied systematically.Therefore,the fabrication defects,microstructure,and mechanical properties of the SLMed NZ30K alloy under different processing parameters were investigated.The results show that there are two types of fabrication defects in the SLMed NZ30K alloy,gas pores and unfused defects.With the increase of the laser energy density,the porosity sharply decreases to the minimum first and then slightly increases.The minimum porosity is 0.49±0.18%.While the microstructure varies from the large grains with lamellar structure inside under low laser energy density,to the large grains with lamellar structure inside&the equiaxed grains&the columnar grains under middle laser energy density,and further to the fine equiaxed grains&the columnar grains under high laser energy density.The lamellar structure in the large grain is a newly observed microstructure for the NZ30K Mg alloy.Higher laser energy density leads to finer grains,which enhance all the yield strength(YS),ultimate tensile strength(UTS)and elongation,and the best comprehensive mechanical properties obtained are YS of 266±2.1 MPa,UTS of 296±5.2 MPa,with an elongation of 4.9±0.68%.The SLMed NZ30K Mg alloy with a bimodal-grained structure consisting of fine equiaxed grains and coarser columnar grains has better elongation and a yield drop phenomenon.

Effect of Cryogenic Treatment on Microstructure and Tribological Property Evolution of Electron Beam Melted Ti6Al4V

Cryogenic treatment was used to improve the tribological properties of Ti6Al4V artificial hip joint implants.Cryogenic treatment at-196℃with different holding time were carried out on Ti6Al4V specimens fabricated using electron beam melting(EBM),and their microstructure and tribological properties evolution were systematically analyzed by scanning electron microscopy(SEM),vickers hardness,and wear tests.The experimental results show that the as-fabricated specimen consists of lamellarαphase andβcolumnar crystal.While,the thickness of lamellarαphase decreased after cryogenic treatment.In addition,it can be found that the fineαphase was precipitated and dispersed between the lamellarαphase with the holding time increase.Vickers hardness shows a trend of first increasing and then decreasing.The wear rate of the specimen cryogenic treated for 24 h is the minimum and the average friction coefficient is 0.50,which is reduced by 14.61%compared with the as-fabricated.The wear mechanism of the as-fabricated specimen is severe exfoliation,adhesive,abrasive,and slight fatigue wear.However,the specimen cryogenic treated for 24 h shows slight adhesive and abrasive wear.It can be concluded that it is feasibility of utilizing cryogenic treatment to reduce the wear of EBMed Ti6Al4V.

Microstructure and Oxidation Behavior of ZrB_(2)-SiC Ceramics Fabricated by Tape Casting and Reactive Melt Infiltration

ZrB_(2)-based ceramics typically necessitate high temperature and pressure for sintering,whereas ZrB_(2)-SiC ceramics can be fabricated at 1500℃using the process of reactive melt infiltration with Si.In comparison to the conventional preparation method,reactive synthesis allows for the more facile production of ultra-high temperature ceramics with fine particle size and homogeneous composition.In this work,ZrSi_(2),B4C,and C were used as raw materials to prepare ZrB_(2)-SiC via combination of tape casting and reactive melt infiltration herein referred to as ZBC ceramics.Control sample of ZrB_(2)-SiC was also prepared using ZrB_(2) and SiC as raw materials through an identical process designated as ZS ceramics.Microscopic analysis of both ceramic groups revealed smaller and more uniformly distributed particles of the ZrB_(2) phase in ZBC ceramics compared to the larger particles in ZS ceramics.Both sets of ceramics underwent cyclic oxidation testing in the air at 1600℃for a cumulative duration of 5 cycles,each cycle lasting 2 h.Analysis of the oxidation behavior showed that both ZBC ceramics and ZS ceramics developed a glassy SiO_(2)-ZrO_(2) oxide layer on their surfaces during the oxidation.This layer severed as a barrier against oxygen.In ZBC ceramics,ZrO_(2) is finely distributed in SiO_(2),whereas in ZS ceramics,larger ZrO_(2) particles coexist with glassy SiO_(2).The surface oxide layer of ZBC ceramics maintains a dense structure because the well-dispersed ZrO_(2) increases the viscosity of glassy SiO_(2),preventing its crystallization during the cooling.Conversely,some SiO_(2) in the oxide layer of ZS ceramics may crystallize and form a eutectic with ZrO_(2),leading to the formation of ZrSiO_(4).This leads to cracking of the oxide layer due to differences in thermal expansion coefficients,weakening its barrier effect.An analysis of the oxidation resistance shows that ZBC ceramics exhibit less increase in oxide layer thickness and mass compared to ZS ceramics,suggesting superior oxidation resistance of ZBC ceramics.

Evolution of microstructure and mechanical properties in multi-layer 316L-TiC composite fabricated by selective laser melting additive manufacturing

In this study,the microstructure and mechanical properties of a multi-layered 316L-TiC composite material produced by selective laser melting(SLM)additive manufacturing process are investigated.Three different layers,consisting of 316L stainless steel,316L-5 wt%TiC and 316L-10 wt%TiC,were additively manufactured.The microstructure of these layers was characterized by optical microscopy(OM)and scanning electron microscopy(SEM).X-ray diffraction(XRD)was used for phase analysis,and the mechanical properties were evaluated by tensile and nanoindentation tests.The microstructural observations show epitaxial grain growth within the composite layers,with the elongated grains growing predominantly in the build direction.XRD analysis confirms the successful incorporation of the TiC particles into the 316L matrix,with no unwanted phases present.Nanoindentation results indicate a significant increase in the hardness and modulus of elasticity of the composite layers compared to pure 316L stainless steel,suggesting improved mechanical properties.Tensile tests show remarkable strength values for the 316L-TiC composite samples,which can be attributed to the embedded TiC particles.These results highlight the potential of SLM in the production of multi-layer metal-ceramic composites for applications that require high strength and ductility of metallic components in addition to the exceptional hardness of the ceramic particles.

Ablation behaviour and mechanical performance of ZrB_(2)-ZrC-SiC modified carbon/carbon composites prepared by vacuum infiltration combined with reactive melt infiltration

The development of advanced aircraft relies on high performance thermal-structural materials,and carbon/carbon com-posites(C/C)composited with ultrahigh-temperature ceramics are ideal candidates.However,the traditional routes of compositing are either inefficient and expensive or lead to a non-uniform distribution of ceramics in the matrix.Compared with the traditional C/C-ZrC-SiC composites prepared by the reactive melt infiltration of ZrSi_(2),C/C-ZrB_(2)-ZrC-SiC composites prepared by the vacuum infiltration of ZrB_(2) combined with reactive melt infiltration have the higher content and more uniform distribution of the introduced ceramic phases.The mass and linear ablation rates of the C/C-ZrB_(2)-ZrC-SiC composites were respectively 68.9%and 29.7%lower than those of C/C-ZrC-SiC composites prepared by reactive melt infiltration.The ablation performance was improved because the volatilization of B_(2)O_(3),removes some of the heat,and the more uniformly distributed ZrO_(2),that helps produce a ZrO2-SiO2 continu-ous protective layer,hinders oxygen infiltration and decreases ablation.

The variation in basal channels and basal melt rates of Pine Island Ice Shelf

In recent years,there has been a significant acceleration in the thinning,calving and retreat of the Pine Island Ice Shelf(PIIS).The basal channels,results of enhanced basal melting,have the potential to significantly impact the stability of the PIIS.In this study,we used a variety of remote sensing data,including Landsat,REMA DEM,ICESat-1 and ICESat-2 satellite altimetry observations,and Ice Bridge airborne measurements,to study the spatiotemporal changes in the basal channels from 2003 to 2020 and basal melt rate from 2010 to 2017 of the PIIS under the Eulerian framework.We found that the basal channels are highly developed in the PIIS,with a total length exceeding 450 km.Most of the basal channels are ocean-sourced or groundingline-sourced basal channels,caused by the rapid melting under the ice shelf or near the groundingline.A raised seabed prevented warm water intrusion into the eastern branch of the PIIS,resulting in a lower basal melt rate in that area.In contrast,a deepsea trough facilitates warm seawater into the mainstream and the western branch of the PIIS,resulting in a higher basal melt rate in the main-stream,and the surface elevation changes above the basal channels of the mainstream and western branch are more significant.The El Ni?o event in 2015–2016 possibly slowed down the basal melting of the PIIS by modulating wind field,surface sea temperature and depth seawater temperature.Ocean and atmospheric changes were driven by El Ni?o,which can further explain and confirm the changes in the basal melting of the PIIS.

Crack elimination and strength enhancement mechanisms of selective laser melted Si-modified Al−Mn−Mg−Er−Zr alloy

In order to increase the processability and process window of the selective laser melting(SLM)-fabricated Al−Mn−Mg−Er−Zr alloy,a novel Si-modified Al−Mn−Mg−Er−Zr alloy was designed.The effect of Si alloying on the surface quality,processability,microstructure,and mechanical properties of the SLM-fabricated alloy was studied.The results showed that introducing Si into the Al−Mn−Mg−Er−Zr alloy prevented balling and keyhole formation,refined the grain size,and reduced the solidification temperature,which eliminated cracks and increased the processability and process window of the alloy.The maximum relative density of the SLM-fabricated Si/Al−Mn−Mg−Er−Zr alloy reached 99.6%.The yield strength and ultimate tensile strength of the alloy were(371±7)MPa and(518±6)MPa,respectively.These values were higher than those of the SLM-fabricated Al−Mn−Mg−Er−Zr and other Sc-free Al−Mg-based alloys.

Formation and Properties of Organic Long Persistent Luminescence Crystals Containing Benzidine Derivatives by Melt Crystallization

Organic molecules that exhibit long persistent luminescence (LPL) are rapidly gaining attention for a variety of applications. In this study, organic molecules with simple structures were selected and organic long persistent luminescence (OLPL) crystals were prepared. The crystal structure of the prepared OLPL crystal was elucidated and the guideline for the design of OLPL crystal was clarified. LPL was observed in OLPL crystals prepared with TMB as the guest molecule and 1,2-bis(diphenylphosphino)ethane as the host molecule. XRD measurements of the OLPL crystals suggest that the guest molecule is a solid solution substituted in the stable crystal structure of the host molecule in a lattice-shrinking direction.

Selective Laser Melting of Novel SiC and TiC Strengthen 7075 Aluminum Powders for Anti-Cracks Application

The aerospace and military sectors have widely used AA7075, a type of 7075 aluminum alloy, due to its exceptional mechanical performance. Selective laser melting (SLM) is a highly effective method for producing intricate metallic components, particularly in the case of aluminum alloys like Al-Si-Mg. Nevertheless, the production of high-strength AA7075 by SLM is challenging because of its susceptibility to heat cracking and elemental vaporization. In this study, AA7075 powders were mechanically mixed with SiC and TiC particles. Subsequently, this new type of AA7075 powder was effectively utilized in green laser printing to create solid components with fine-grain strengthening microstructures consisting of equiaxial grains. These as-printed parts exhibit a tensile strength of up to 350 MPa and a ductility exceeding 2.1%. Hardness also increases with the increasing content of mixed powder, highlighting the essential role of SiC and TiC in SLM for improved hardness and tensile strength performance. .

Climate prediction of the seasonal sea-ice early melt onset in the Bering Sea

基于大尺度环流异常对海冰消融的影响过程,本文采用年际增量预测方法研制了白令海季节性海冰早期消融开始日期(EMO)的统计预测模型.预测模型选取了3个具有明确物理意义的预测因子:1月波弗特高压,前期11月东西伯利亚地区海平面气压,以及11月东欧平原积雪覆盖率。1月波弗特高压可以通过海气相互作用影响白令海地区海温异常,该海温异常能够从1月持续到3月,进而影响白令海EMO.11月东西伯利亚地区海平面气压与11月至次年2月北太平洋中纬度东部海温密切相关。伴随着北太平洋中纬度东部冷海温异常的出现,白令海地区会出现暖海温异常,进而导致白令海海冰范围减少,EMO较晚.1月北极偶极子异常是11月东欧平原积雪覆盖率影响次年白令海EMO的桥梁之一.1981-2022年的交叉检验结果表明:统计模型对白令海EMO具有较好的预测能力,预测与观测的EMO之间时间相关系数达到了0.45,超过了99%的置信水平.统计模型对白令海EMO正常年份和异常年份的预测准确率分别为60%和41%.

Selective laser melted AZ91D magnesium alloy with superior balance of strength and ductility

In the context of global carbon neutrality, the application of lightweight magnesium alloys is becoming increasingly attractive. In this study, selective laser melting(SLM) was employed to achieve nearly full dense and crack-free AZ91D components with fine equiaxed grain structure. The formation mechanism of typical pore defects(gas pore, lack-of-fusion pore and keyhole pore) and melting modes(keyhole mode and conduction mode) were systematically studied by varying the laser power and scanning speed. The morphology and volume fraction of the pores under different processing conditions were characterized. A criterion based on the depth-to-width ratio of the melt pool was established to identify different melting modes. The strength and ductility(tensile strength up to 340 MPa and uniform elongation of 8.9%)of the as deposited AZ91D are far superior to those of the casting components and are comparable to those of its wrought counterparts.The superior balance of strength and ductility of SLMed AZ91D, as well as the negligible anisotropic properties are mainly ascribed to the extremely fine equiaxed grain structure(with average grain size of ~1.2 μm), as well as the discontinuous distribution of β-Al_(12)Mg_(17) phases. It thus provides an alternative way to fabricate high-strength magnesium alloys with complex geometry.