A Novel Physics-Based Model for Predicting Melt Pool Dimensions in Laser Powder Bed Fusion Process

Abstract This paper employed a scaling analysis to represent the processing parameters, affecting the melting process in the dimensionless numbers, identify the relationships of these dimensionless numbers, and develop semi-empirical correlations to predict the width and depth of the melt pool. To develop the correlations, Ti-6Al-4V powder was used to print 38 tracks at various processing conditions. The correlations were then fit into this experimental data using python code to find the constants of the correlations. The correlations were then used to predict the depth and width of the melt pools. It was found that the mean discrepancy between the predicted melt pool dimensions and the experiment is 7%. To evaluate the accuracy of the correlation in predicting the melt pool dimensions of the materials never used during the development of the correlations, the melt pool depth of some tracks made out of stainless steel 316L printed at various conditions was predicted using the model, and it was found that the mean discrepancy between the predicted melt pool depth and experiment is 11%.