A rapid experimental workflow for studying melt track scaling in laser powder bed fusion using high-precision metal template substrates

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.