Process window prediction in stainless steel selective laser melting using various energy densities: laser power, scan speed, and defocusing distance

The process window of selective laser melting (SLM), a set of optimum process parameters, is crucial for producing defect-free components with excellent mechanical properties. This study aims to predict the optimum process window for SLM of stainless steel by varying the defocusing distance (f) which changes the laser beam diameter (d) and using laser power (P) and scan speed (V) as process parameters. The process window was predicted using empirical formulae related to the energy density equations, instead of the conventional approach based on simple experimental results. To predict the process window, we analyzed the melt pool geometry of components with different features, such as depth (D), width (W), layer thickness (t), and hatch distance (h). Using the energy density equation, we correlated the effect of these process variables on the melt pool geometry and derived empirical equations. The upper limit of the process window (D/W) was strongly correlated with local applied energy and expressed as P & LE; 34Vd(2). The lower limits, D/t and W/h, showed good correlation with linear energy density and laser energy density, respectively, and expressed as P > 2.16Vd and P < 0.13V. Finally, we used these empirical equations to predict the process window, which was experimentally verified.