Repository logo

Infoscience

  • English
  • French
Log In
Logo EPFL, École polytechnique fédérale de Lausanne

Infoscience

  • English
  • French
Log In
  1. Home
  2. Academic and Research Output
  3. Journal articles
  4. Fast and accurate laser powder bed fusion metamodels predicting melt pool dimensions, effective laser absorptivity and lack of fusion defects
 
research article

Fast and accurate laser powder bed fusion metamodels predicting melt pool dimensions, effective laser absorptivity and lack of fusion defects

Schlenger, Lucas  
•
Nasab, Milad Hamidi  
•
Masinelli, Giulio
Show more
May 15, 2025
Journal of Manufacturing Processes

The significant computational expenses associated with simulating the Laser Powder Bed Fusion (LPBF) process often restrict the insights gained from modeling endeavors to specific combinations of process parameters, hindering broader conclusions. In this study, we employ a classical Design of Experiments approach on results obtained by multiphase Finite Element simulations. Utilizing this framework, we derive quadratic metamodels for the dimensions of the melt pool, enabling predictions of melt pool width, depth, and length across a wide spectrum of processing conditions. Notably, our findings indicate that as few as 25 simulations can suffice to predict melt pool dimensions in conduction mode LPBF across varying laser power, velocity, initial temperature, and spot size parameters. Among other insights, the metamodels uncover and quantify the substantial influence of initial temperature (the local temperature of the volume preceding the laser interaction). Additionally, rare insights regarding the melt pool sensitivity towards the laser spot size are provided. Furthermore, our investigation delves into laser interactions with different phases (powder, liquid, solid) across diverse processing conditions to establish a net global absorption coefficient. These analyses underscore that, under conventional process conditions, most of the incident laser intensity falls onto the liquid phase during conduction mode LPBF simulations of 316L stainless steel and Ti-6Al-4V. However, the laser spot size significantly affects the laser intensity interacting with the liquid phase, warranting consideration of laser spot size dependent absorptivity values in part-scale models. Lastly, employing straightforward geometric simulations, we derive a full processing map predicting the occurrence of Lack of Fusion defects, based on calculated melt pool dimensions and the associated scanning strategy.

  • Files
  • Details
  • Metrics
Type
research article
DOI
10.1016/j.jmapro.2025.03.006
Scopus ID

2-s2.0-105000211983

Author(s)
Schlenger, Lucas  

École Polytechnique Fédérale de Lausanne

Nasab, Milad Hamidi  

École Polytechnique Fédérale de Lausanne

Masinelli, Giulio

Empa - Swiss Federal Laboratories for Materials Science and Technology

Boillat, Eric  

École Polytechnique Fédérale de Lausanne

Jhabvala, Jamasp  

École Polytechnique Fédérale de Lausanne

Ivas, Toni

Empa - Swiss Federal Laboratories for Materials Science and Technology

Navarre, Claire  

École Polytechnique Fédérale de Lausanne

Esmaeilzadeh, Reza  

École Polytechnique Fédérale de Lausanne

Yang, Jian

Empa - Swiss Federal Laboratories for Materials Science and Technology

Leinenbach, Christian

Empa - Swiss Federal Laboratories for Materials Science and Technology

Show more
Date Issued

2025-05-15

Published in
Journal of Manufacturing Processes
Volume

141

Start page

1337

End page

1353

Subjects

Design of experiments

•

Lack of fusion defects

•

Laser absorptivity

•

Laser powder bed fusion

•

Melt pool dimensions

•

Numerical simulation

Editorial or Peer reviewed

REVIEWED

Written at

EPFL

EPFL units
LMTM  
FunderFunding(s)Grant NumberGrant URL

SMARTAM project from the Strategic Focus Area Advanced Manufacturing (SFA-AM) , a strategic initiative of the ETH Board, Switzerland

PX Group

Available on Infoscience
April 2, 2025
Use this identifier to reference this record
https://infoscience.epfl.ch/handle/20.500.14299/248490
Logo EPFL, École polytechnique fédérale de Lausanne
  • Contact
  • infoscience@epfl.ch

  • Follow us on Facebook
  • Follow us on Instagram
  • Follow us on LinkedIn
  • Follow us on X
  • Follow us on Youtube
AccessibilityLegal noticePrivacy policyCookie settingsEnd User AgreementGet helpFeedback

Infoscience is a service managed and provided by the Library and IT Services of EPFL. © EPFL, tous droits réservés