biostudies-literatureGetley ACMEngineering and Physical Sciences Research Council (EPSRC)IPG Photonics/Royal Academy of Engineering Senior Research Fellowship in SEARCHRoyal Academy of Engineeringe13652https://www.ebi.ac.uk/biostudies/studies/S-EPMC12948290biostudies-literatureUnknown13(12)Understanding vaporization phenomena in laser powder bed fusion (LPBF) additive manufacturing has proven challenging; the links between laser-induced metal vaporization, rate of elemental loss, and composition irregularities remain unclear. Here, the vapor plume composition and preferential vaporization effect is quantified during LPBF, using in situ 1 kHz laser-induced breakdown spectroscopy with correlative X-ray synchrotron radiography, multi-physics simulations, and energy dispersive X-ray spectroscopy. It is demonstrated that vaporization increases under keyhole mode, and preferential vaporization causes elemental loss rates of Ni ≈ Fe > Cr > Mo in a Ni-based superalloy, IN625. It is found that the melt pool temperature (T ≈2300 K) can be approximated by cross-referencing vapor pressuAdvanced science (Weinheim, Baden-Wurttemberg, Germany)Quantifying Additive Manufacturing Vapor Plumes Using Laser-Induced Breakdown Spectroscopy, Synchrotron X-Ray Radiography and Simulations.PMC12948290EP/ N509577/1RCSRF2324-18-71EP/W006774/1EP/V061798/1CiET1819/10EP/ R511638/1EP/P006566/1W522193/1EP/2453539EP/W003333/1EP/W037483/1Towrie MMajkut MHocine SLee PDRack AGetley ACMPanwisawas CLeung CLAShinjo JfalseQuantifying Additive Manufacturing Vapor Plumes Using Laser-Induced Breakdown Spectroscopy, Synchrotron X-Ray Radiography and Simulations.Understanding vaporization phenomena in laser powder bed fusion (LPBF) additive manufacturing has proven challenging; the links between laser-induced metal vaporization, rate of elemental loss, and composition irregularities remain unclear. Here, the vapor plume composition and preferential vaporization effect is quantified during LPBF, using in situ 1 kHz laser-induced breakdown spectroscopy with correlative X-ray synchrotron radiography, multi-physics simulations, and energy dispersive X-ray spectroscopy. It is demonstrated that vaporization increases under keyhole mode, and preferential vaporization causes elemental loss rates of Ni ≈ Fe > Cr > Mo in a Ni-based superalloy, IN625. It is found that the melt pool temperature (T ≈2300 K) can be approximated by cross-referencing vapor pressu2026-01-01T00:00:00Z2026 Feb2026-07-16T22:15:09.153Z2026-07-12T03:08:47.502ZS-EPMC129482904141283510.1002/advs.202513652