Scaling analysis for rapid estimation of lack of fusion porosity in laser powder bed fusion

Lack-of-fusion porosity due to insufficient melting of the adjacent tracks and successive layers is a persistent problem in laser powder bed fusion (LPBF). A novel functional relation is proposed here following dimensional analysis for rapid estimation of the lack-of-fusion porosity fraction as a function of important process variables and alloy properties. The estimated values of the porosity fractions are found to be in fair agreement with the corresponding independent experimentally measured results for LPBF of five commonly used alloys for a wide range of process conditions. The proposed functional relation is used further to construct a set of process maps that can aid in the selection of important LPBF conditions to avoid lack-of-fusion porosity on the shop floor without doing any calculations.

Automated summary

A novel functional relation is proposed for rapid estimation of lack-of-fusion porosity fraction in laser powder bed fusion (LPBF). The estimated values are in good agreement with experimental results for five commonly used alloys and a wide range of process conditions. The functional relation is further used to construct process maps for avoiding lack-of-fusion porosity on the shop floor.