A rapid experimental workflow for studying melt track scaling in laser powder bed fusion using high-precision metal template substrates
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40964_2025_Article_1145.pdf
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2.29 MB
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d95559d291051fde59a61c9576f060b4
Author(s)
Weissbach, Reimar
Penny, Ryan W.
Hart, A. J.
Date Issued
June 26, 2025
Journal
Progress in Additive Manufacturing
Publisher
Springer International Publishing
Citation
Weissbach, R., Penny, R.W. & Hart, A.J. A rapid experimental workflow for studying melt track scaling in laser powder bed fusion using high-precision metal template substrates. Prog Addit Manuf 10, 8695–8706 (2025).
Version
Final published version
Abstract
Development and qualification of process parameters in laser powder bed fusion (LPBF) involves many variables. At the outset of development, whether transferring known parameters to a new machine, or exploring a new material, single-track and single-layer experiments are a convenient means of down-selecting key variables and exploring parameter scaling behavior. We present an experimental workflow for single-layer LPBF experiments using high-precision metal template substrates, overcoming challenges with precision single-layer alignment in LPBF systems and enabling efficient processing and cross-sectional analysis. Templates are fabricated using chemical etching and machining, and are characterized using optical profilometry and X-ray transmission imaging of powder layers. Using the etched templates, a single-track parameter study is performed in SS316 including three powder layer thicknesses, and spanning common laser melting modes (lack-of-fusion, conduction, and keyhole mode). Analysis of melt track geometries using automated image processing allows a scaling law to be applied to define the process window, quantifying the amount of material added with increasing powder layer thickness. Single-track results are verified with raster scanning experiments, showing the potential to transfer single-track results to full LPBF builds.
MIT Department
Massachusetts Institute of Technology. Department of Mechanical Engineering
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Creative Commons Attribution
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DOI of Published Version
https://doi.org/10.1007/s40964-025-01145-x
