| Abstract Scope |
Laser-based powder bed fusion of metals (PBF-LB/M) enables the manufacture of complex geometries for high-performance applications. However, process variations can lead to dimensional inaccuracies or microstructural issues affecting the overall part quality and limiting applications. In consequence, there is a need for efficient qualification methods to ensure part consistency, reliability, and reproducibility. The proposed qualification approach leverages key scanning system data to simulate the process at both micro- and macro-scales. The method enhances existing analytical models to simulate melt pool morphology by incorporating scanning data containing speed, acceleration, deceleration, and default process scanning parameters such as polygon delays. In addition, the method uses laser beam positions to simulate geometry outcomes for macro-scale qualification approaches. By using more representative speed profiles and actual laser paths, the proposed method offers a practical and efficient process qualification strategy, improving accuracy and confidence in part performance. |