The shape variation of the laser beam is evidently observed in the laser powder bed fusion (LPBF) process because of changes in laser incidence angle and misalignment between the build plate and the laser focus plane. This issue is particularly relevant in large-scale LPBF systems where the laser beam needs to scan a large build area. However, most LPBF modeling studies assume vertical laser radiation. The heat transfer, melt pool, and solidification evolution due to the laser shape variation have not been well addressed and quantified. In the present study, the temperature distribution, melt pool geometry and flow dynamics are captured via numerical modelling, and the grain morphology is characterized under various laser incidence angles. The results show that the melt pool depth becomes shallower, and the width is near the beam size as the laser beam becomes more elongated. The beam shape variation can affect the liquid flow pattern with increasing incidence angle, resulting in a larger vortex at the front of the melt pool and a smaller vortex at the rear of the melt pool. The thermal gradient increases and the solidification rate decreases as the laser incident angle becomes larger. The present study enhances the understanding of multi-physics in the LPBF process.

The electrochemical reduction of carbon dioxide (CO₂RR) requires access to ample gaseous CO₂and liquid water to fuel reactions at high current densities for industrial-scale applications. Substantial improvement of the CO₂RR rate has largely arisen from positioning the catalyst close to gas-liquid interfaces, such as in gas-diffusion electrodes. These requirements add complexity to an electrode design that no longer consists of only a catalyst but also a microporous and nanoporous network of gas-liquid-solid interfaces of the electrode. In this three-dimensional structure, electrode wettability plays a pivotal role in the CO₂RR because the affinity of the electrode surface by water impacts the observed electrode reactivity, product selectivity, and long-term stability. All these performance metrics are critical in an industrial electrochemical process. This review provides an in-depth analysis of electrode wettability's role in achieving an efficient, selective, and stable CO₂RR performance. We first discuss the underlying mechanisms of electrode wetting phenomena and the foreseen ideal wetting conditions for the CO₂RR. Then we summarize recent advances in improving cathode performance by altering the wettability of the catalyst layer of gas-diffusion electrodes. We conclude the review by discussing the current challenges and opportunities to develop efficient and selective cathodes for CO₂RR at industrially relevant rates. The insights generated from this review could also benefit the advancement of other critical electrochemical processes that involve multiple complex flows in porous electrodes, such as electrochemical reduction of carbon monoxide, oxygen, and nitrogen.