Understanding Melt Pool Behavior of 316L Stainless Steel in Laser Powder Bed Fusion Additive Manufacturing

Abstract

In the laser powder bed fusion additive manufacturing process, the quality of fabrications is intricately tied to the laser–matter interaction, specifically the formation of the melt pool. This study experimentally examined the intricacies of melt pool characteristics and surface topography across diverse laser powers and speeds via single-track laser scanning on a bare plate and powder bed for 316L stainless steel. The results reveal that the presence of a powder layer amplifies melt pool instability and worsens irregularities due to increased laser absorption and the introduction of uneven mass from the powder. To provide a comprehensive understanding of melt pool dynamics, a high-fidelity computational model encompassing fluid dynamics, heat transfer, vaporization, and solidification was developed. It was validated against the measured melt pool dimensions and morphology, effectively predicting conduction and keyholing modes with irregular surface features. Particularly, the model explained the forming mechanisms of a defective morphology, termed swell-undercut, at high power and speed conditions, detailing the roles of recoil pressure and liquid refilling. As an application, multiple-track simulations replicate the surface features on cubic samples under two distinct process conditions, showcasing the potential of the laser–matter interaction model for process optimization.

Metal Laser-Based Powder Bed Fusion Process Development Using Optical Tomography

“…Referring to experiments performed on the Inconel 718 ratio, this low value indicates that the process is on the edge of transitioning from conductive mode to keyhole [39,40]. For 316 L, Zhang et al measured a similar ratio when the scan speed was 870 mm/s but with slightly higher laser power, i.e., 260 W, and a 50 µm layer thickness [41]. The conclusion is that the specimen C2 parameters-235 W and 920 mm/s-are very close to the process window's upper edge.…”