Static Magnetic Field Impact on Laser Weld Bead Morphology of Sn-10%wt.Pb Alloy

Additive manufacturing (AM) offers significant potential but faces challenges in controlling rapid solidification processes due to thermal conditions. The application of magnetic fields provides a promising path to influence liquid metal behavior during solidification. Thermoelectromagnetic convection (TEMC) is one of the mechanisms by which an applied static magnetic field can induce melt flow, where thermal gradients at the solid–liquid interface generate thermoelectric currents, and in the presence of an external magnetic field induce Lorentz force that drives liquid convection, leading to enhanced heat transfer. This study investigates the impact of moderate static magnetic fields on the laser melting process of a Sn-10%wt.Pb alloy. It is found that applying a magnetic field significantly widens and deepens laser weld beads. Bead depth and width under different field strengths and orientations are measured. Numerical models are developed to calculate the TEMC current distribution and flow in the melt pool.