Mesoscale multilayer multitrack modeling of melt pool physics in laser powder bed fusion of lattice metal features

This paper reports on the development of a mesoscale multiphysics numerical model for predicting the dimensions of melt pool zones in Laser Powder Bed Fusion process, in a multilayer and multitrack application dedicated to the manufacturing of lattice metal features. In such context, a clear need emerges to study laser-matter interaction regarding the persisting questions surrounding the comprehension of melt pool. An experimental campaign involving thin pillars made of the nickel-based superalloy IN718 is presented, highlighting the complexity introduced by the thin tracks superposition. Then, a continuous mesoscale numerical model, considering heat transfer, melt pool flow, and vaporization phenomena, and its extension to multilayer-multitrack simulation is detailed. Some discussions about the numerical approach and its ability to predict the global morphology and dimensions of melt pool zones and resulting tracks after solidification are proposed. Finally, comparisons between the experiments and the numerical model show good agreement, with a maximum relative error of 8 % observed for remelted zone depth. This study demonstrates the capability of the present approach to help in understanding the influence of process parameters on melt pool shape and, thereafter, to determine process parameters to optimize for lattice features building.