Multi-scale modelling for optimization of process parameters of laser powder bed fusion processed Inconel 718 surrogate part

This work uses an analytical and multi-scale thermo-mechanical numerical model to optimise the process parameter to prevent porosity while reducing the distortion in the surrogate part. Taguchi's experimental design technique was used to identify the effect of process parameters on melt pool evolution. A dimensionless relative melt pool depth ratio (d*) ensures the extent of densification in the simulated part for various processing parameters. The Taguchi analysis outcome revealed an increase in d*, solid ratio, residual stress and distortion with increased laser power while a contrary effect with increased hatch spacing and scan speed. A strong interaction is observed for melt pool metrics and residual stress evolution. However, the interactions for re-sidual stress and distortion evolution are more prominent, showing the influence of process pa-rameters on energy density and thermal gradient evolution. The ANOVA analysis also shows a strong influence of process parameters on melt pool development and residual stress evolution. However, for solid ratio development, scan speed shows an insignificant effect. These observa-tions from meso-scale analysis aids in process parameter selection for defect free part fabrication. A reduction in the VED reduced the magnitude of accumulated residual stresses in the surrogate component, thereby reducing the maximum distortion in the part. A decrease of 8.33 % in maximum distortion is observed for a similar to 20 % reduction in the VED.