SIM-AM 2025

Evaluation of Material Consolidation and Molten Pool Behavior Under Different Powder Layer Thicknesses for IN718 in PBF-LB

  • Redford, Jesse (NIST)
  • Weaver, Jordan (NIST)
  • Deisenroth, David (NIST)
  • Mekhontsev, Sergey (NIST)
  • Lane, Brandon (NIST)
  • Levine, Lyle (NIST)

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A fundamental but possibly insufficiently understood aspect of laser powder bed fusion (PBF-LB) metal based additive manufacturing is the relationship between the powder layer thickness, scanning conditions, and the consolidation behavior of molten pool within a layer. This presentation will provide an overview of the measurement results from the AM-Bench 2025-06 challenge series [1] characterizing the fused layer structures (surface and subsurface) of Inconel 718 tracks fabricated under three conditions: bare plate, 80 μm powder layer, and 160 μm powder layer for a fixed set of primary parameters including pad geometries, laser power, scanning speed, and hatch spacing. The pad surface topography challenge (CHAL-AMB2025-06-PST) provides detailed surface roughness and fused layer thickness measurements of different regions of the fabricated pads. For this challenge a definition of the fused layer thickness and new measurement technique are introduced to remove operator subjectivity, providing a robust quantitative evaluation to improve the accuracy of model-measurement comparisons. In addition, the pad melt pool geometry (CHAL-AMB2025-06-PMPG) challenge includes geometrical measurements (depth, width, etc.) describing the overlapping laser tracks from cross-sections taken at specified locations of all pads. Additional metrics from the cross-sections include the total solidified area above the substrate and the total dilution area below the substrate. In-situ measurements including location-specific liquid and solid cooling rates, and location specific time above melting will also be discussed. Finally, observations and trends regarding melt pool behavior under the investigated conditions will be presented and commentary on the agreement between measurement results and the predictions submitted by challenge participants will be discussed.