Aeroacoustic signatures reveal fast transient dynamics of vapor-jet-driven cavity oscillations in metallic additive manufacturing
Aeroacoustic emissions from intense evaporation are widely measured yet often treated as noisy byproducts and used mainly in empirical monitoring. Here, we show that airborne sound encodes physics-governed sub-millisecond fingerprints of vapor-jet dynamics in excessive vaporization, exemplified by vapor keyholes in laser metal processing. From first principles, we develop a vapor-jet-cavity oscillation framework and incorporate it into an aeroacoustic formulation, thereby coupling measured sound to transient cavity depth and oscillation frequency. Reconciled with synchronized multimodal in-situ data, airborne acoustics enable accurate tracking of vapor-cavity properties within tens to hundreds of microseconds. Combined with newly discovered correlations, cavity-jet-acoustic theory recasts the transition from steady, pore-free to pore-shedding vaporizations as a critical-frequency event. Aeroacoustic emissions thus become scalable, physics-guided, and cost-efficient probes of rapidly evolving liquid-vapor systems.