About this Abstract |
| Meeting |
MS&T26: Materials Science & Technology
|
| Symposium
|
Additive Manufacturing Modeling, Simulation, and Machine Learning: Microstructure, Mechanics, and Process
|
| Presentation Title |
Beyond Single-Track Maps: Multi-Dimensional Process Mapping for LPBF Thermal Behavior and Microstructural Control |
| Author(s) |
Alaa Olleak, Moataz Attallah, Dorothy Tomlinson |
| On-Site Speaker (Planned) |
Alaa Olleak |
| Abstract Scope |
Single-track-based process maps are widely used to evaluate LPBF behavior across power–speed combinations and identify acceptable processing windows. However, parameters selected from single-track maps may produce different outcomes when applied to real parts, where heat buildup shifts the acceptable process window. In this study, a simulation-based framework is developed to establish scan-strategy-aware, multi-dimensional process maps that incorporate stripe width, hatch spacing, and pre-deposition temperature in addition to the widely used power and speed. After calibration and validation using single-track simulations, multi-track simulations are performed to predict steady-state melt-pool dimensions and cooling rate. The results reveal a significant and quantifiable shift in the acceptable process window, along with systematic cooling-rate variations driven by scan-strategy parameters. Experimental validation supports the predicted cooling-rate trends and confirms the associated microstructural effects, highlighting the need to move beyond single-track process maps toward multi-track, multi-dimensional maps for LPBF thermal behavior. |