Measurements of Melt Pool Geometry and Cooling Rates of Individual Laser Traces on IN625 Bare Plates

The complex physical nature of the laser powder bed fusion (LPBF) process warrants use of multiphysics computational simulations to predict or design optimal operating parameters or resultant part qualities such as microstructure or defect concentration. Many of these simulations rely on tuning based on characteristics of the laser-induced melt pool, such as the melt pool geometry (length, width, and depth). Additionally, many of numerous interacting variables that make the LPBF process so complex can be reduced and controlled by performing simple, single-track experiments on bare (no powder) substrates, yet still produce important and applicable physical results. The 2018 Additive Manufacturing Benchmark (AM Bench) tests and measurements were designed for this application. This paper describes the experiment design for the tests conducted using LPBF on bare metal surfaces, and the measurement results for the melt pool geometry and melt pool cooling rate performed on two LPBF systems. Several factors, such as accurate laser spot size, were determined after the 2018 AM Bench conference, with results of those additional tests reported here.