Analytical Analysis and Experimental Validation of the Effects of Process Parameters on Meltpool Size During the Selective Laser Melting (SLM) of Inconel 718

Selective laser melting (SLM) is an advanced metal additive manufacturing (AM) process used in the automobile, aerospace, and electronics industry to manufacture complex components. During the printing process, the meltpool is created, which controls the build parts' microstructure and quality. So, it is crucial to determine the meltpool size and establish the effect of process parameters on the meltpool dimensions. An analytical approach is utilized to determine the meltpool size. These predicted data from the analytical approach were validated with experimental data. Inconel 718 powder was used to fabricate the cubed shaped samples with a combination of different SLM process parameters; namely, laser power; scanning speed; and hatching space. Meltpool dimensions were measured from the microstructure images of the samples. After the validation of analytical data with experimental data, the effect of SLM process parameters on meltpool dimensions was established. The result shows that the SLM process parameters significantly affects meltpool geometry, which is very useful for selecting suitable process parameters.