About this Abstract |
| Meeting |
2027 TMS Annual Meeting & Exhibition
|
| Symposium
|
Additive Manufacturing for Energy Industry
|
| Presentation Title |
Analytical prediction of melt-track geometry and hatch spacing in laser powder bed fusion of nickel-based superalloys |
| Author(s) |
Mahdi Alishavandi, Rahmi Ünal, Metin Uymaz Salamci |
| On-Site Speaker (Planned) |
Metin Uymaz Salamci |
| Abstract Scope |
Laser powder bed fusion of nickel-based superalloys requires control of melt-track geometry to limit lack of fusion and keyhole-related defects. This work presents a unified analytical framework that relates track width, height, depth, contact angle, powder-layer thickness, absorption, and hatch spacing. Dimensionless wetting shape factors are introduced to calculate track area and volume for acute and obtuse contact angles, while quadratic relationships connect the powder-layer thickness to the track dimensions. A normalized-enthalpy formulation links laser energy input to melt-pool penetration and the transition from conduction to keyhole melting. The framework was validated using IN625 and IN738LC single-track and multitrack experiments, with additional verification using aluminum alloys. For IN738LC, the model captures the evolution from the initial single track to steady-state overlap and identifies hatch-spacing ranges that promote sufficient fusion. The approach provides a practical basis for process-window development, track monitoring, and defect mitigation during additive manufacturing of high-temperature nickel-based superalloys. |
| Proceedings Inclusion? |
Planned: |
| Keywords |
Additive Manufacturing, High-Temperature Materials, Modeling and Simulation |