Towards Full-Scale Prediction of Melt Pool Dimensions: Combining Experimental Studies with Process Simulations

Paper in proceeding, 2025

The next big hurdle to large-scale industrialisation of additive manufacturing (AM) is the ability to simulate the process accurately. A finite element-based AM module developed by Thermo-Calc is presented which estimates both thermodynamic and thermophysical properties from thermodynamic databases to accurately simulate powder bed fusion process. The solver can account for phenomena such as fluid flow, keyhole formation and absorptivity. Calculations provide the user with information about time-temperature variation and sizes of individual melt pools. In this study, we printed samples using Al-HS1 and 316L stainless steel with linear energy density (Power/Speed ratio) from 0.15-0.82 J/mm and 0.11-0.84 J/mm respectively to validate melt pool dimensions in processing windows extremes. Benefit of this study will be in validating the accuracy of simulation tools to help in industrial implementation and help improve productivity of AM processes.