Theoretical Analysis of the Process Window for Laser Powder-Bed Fusion for Infrared and Green Lasers Using Rosenthal Approximation.
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| Title: | Theoretical Analysis of the Process Window for Laser Powder-Bed Fusion for Infrared and Green Lasers Using Rosenthal Approximation. |
|---|---|
| Authors: | Ho, Vi1 (AUTHOR), Ladani, Leila1 (AUTHOR), Razmi, Jafar1 (AUTHOR) |
| Source: | Materials (1996-1944). Jun2026, Vol. 19 Issue 12, p2487. 29p. |
| Subjects: | Powder bed fusion, Infrared lasers, Selective laser melting, Melting, Analytical solutions, Lasers, Applied sciences |
| Abstract: | Lack of fusion (LOF) is a dominant defect in Laser Powder-Bed Fusion (PBF-LB/M) caused by insufficient overlapping between adjacent melt pools. This study introduces a rapid, first-principles model based on Rosenthal's analytical solution for a moving point heat source to predict melt pool geometry. Using geometric criteria, the model evaluates whether the melt pool width exceeds the hatching distance and whether the melt pool depth exceeds the layer thickness. Based on these conditions, LOF-based process windows are constructed by plotting laser power against scanning speed and classifying each parameter combination as either LOF or no LOF. The process developed here for constructing LOF process windows can be applied to metallic PBF-LB/M systems. As PBF-LB/M of copper is commonly associated with LOF defects, the approach is examined for pure copper by evaluating a range of laser powers and scanning speeds for both near-infrared (NIR) (1064 nm) and green (515 nm) lasers using copper-specific absorptivity values. The resulting process windows are validated against literature-reported relative density data for pure copper, using high relative density values as indicators of full fusion and lower relative density values reported with LOF characteristics as indicators of lack of fusion. For a 30 µm layer thickness, the predicted LOF boundary agreed with 43 of 46 literature-reported copper PBF-LB/M data points when the data were classified using relative density and reported defect morphology. Sensitivity analysis showed that the agreement changed modestly when the relative-density threshold was reduced from 99% to 98.5% and 98% and that near-boundary classifications were sensitive to the selected absorptivity within the reported NIR range. The agreement supports the use of the framework as a preliminary screening tool for identifying LOF-prone parameter regions. By providing a fast, physics-based screening tool for LOF-limited process windows, this framework offers a computationally efficient alternative to high-fidelity numerical simulations commonly used in PBF-LB/M process development. [ABSTRACT FROM AUTHOR] |
| Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.) | |
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| Items | – Name: Title Label: Title Group: Ti Data: Theoretical Analysis of the Process Window for Laser Powder-Bed Fusion for Infrared and Green Lasers Using Rosenthal Approximation. – Name: Author Label: Authors Group: Au Data: <searchLink fieldCode="AR" term="%22Ho%2C+Vi%22">Ho, Vi</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Ladani%2C+Leila%22">Ladani, Leila</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Razmi%2C+Jafar%22">Razmi, Jafar</searchLink><relatesTo>1</relatesTo> (AUTHOR) – Name: TitleSource Label: Source Group: Src Data: <searchLink fieldCode="JN" term="%22Materials+%281996-1944%29%22">Materials (1996-1944)</searchLink>. Jun2026, Vol. 19 Issue 12, p2487. 29p. – Name: Subject Label: Subjects Group: Su Data: <searchLink fieldCode="DE" term="%22Powder+bed+fusion%22">Powder bed fusion</searchLink><br /><searchLink fieldCode="DE" term="%22Infrared+lasers%22">Infrared lasers</searchLink><br /><searchLink fieldCode="DE" term="%22Selective+laser+melting%22">Selective laser melting</searchLink><br /><searchLink fieldCode="DE" term="%22Melting%22">Melting</searchLink><br /><searchLink fieldCode="DE" term="%22Analytical+solutions%22">Analytical solutions</searchLink><br /><searchLink fieldCode="DE" term="%22Lasers%22">Lasers</searchLink><br /><searchLink fieldCode="DE" term="%22Applied+sciences%22">Applied sciences</searchLink> – Name: Abstract Label: Abstract Group: Ab Data: Lack of fusion (LOF) is a dominant defect in Laser Powder-Bed Fusion (PBF-LB/M) caused by insufficient overlapping between adjacent melt pools. This study introduces a rapid, first-principles model based on Rosenthal's analytical solution for a moving point heat source to predict melt pool geometry. Using geometric criteria, the model evaluates whether the melt pool width exceeds the hatching distance and whether the melt pool depth exceeds the layer thickness. Based on these conditions, LOF-based process windows are constructed by plotting laser power against scanning speed and classifying each parameter combination as either LOF or no LOF. The process developed here for constructing LOF process windows can be applied to metallic PBF-LB/M systems. As PBF-LB/M of copper is commonly associated with LOF defects, the approach is examined for pure copper by evaluating a range of laser powers and scanning speeds for both near-infrared (NIR) (1064 nm) and green (515 nm) lasers using copper-specific absorptivity values. The resulting process windows are validated against literature-reported relative density data for pure copper, using high relative density values as indicators of full fusion and lower relative density values reported with LOF characteristics as indicators of lack of fusion. For a 30 µm layer thickness, the predicted LOF boundary agreed with 43 of 46 literature-reported copper PBF-LB/M data points when the data were classified using relative density and reported defect morphology. Sensitivity analysis showed that the agreement changed modestly when the relative-density threshold was reduced from 99% to 98.5% and 98% and that near-boundary classifications were sensitive to the selected absorptivity within the reported NIR range. The agreement supports the use of the framework as a preliminary screening tool for identifying LOF-prone parameter regions. By providing a fast, physics-based screening tool for LOF-limited process windows, this framework offers a computationally efficient alternative to high-fidelity numerical simulations commonly used in PBF-LB/M process development. [ABSTRACT FROM AUTHOR] – Name: AbstractSuppliedCopyright Label: Group: Ab Data: <i>Copyright of Materials (1996-1944) is the property of MDPI and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.) |
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| RecordInfo | BibRecord: BibEntity: Identifiers: – Type: doi Value: 10.3390/ma19122487 Languages: – Code: eng Text: English PhysicalDescription: Pagination: PageCount: 29 StartPage: 2487 Subjects: – SubjectFull: Powder bed fusion Type: general – SubjectFull: Infrared lasers Type: general – SubjectFull: Selective laser melting Type: general – SubjectFull: Melting Type: general – SubjectFull: Analytical solutions Type: general – SubjectFull: Lasers Type: general – SubjectFull: Applied sciences Type: general Titles: – TitleFull: Theoretical Analysis of the Process Window for Laser Powder-Bed Fusion for Infrared and Green Lasers Using Rosenthal Approximation. Type: main BibRelationships: HasContributorRelationships: – PersonEntity: Name: NameFull: Ho, Vi – PersonEntity: Name: NameFull: Ladani, Leila – PersonEntity: Name: NameFull: Razmi, Jafar IsPartOfRelationships: – BibEntity: Dates: – D: 15 M: 06 Text: Jun2026 Type: published Y: 2026 Identifiers: – Type: issn-print Value: 19961944 Numbering: – Type: volume Value: 19 – Type: issue Value: 12 Titles: – TitleFull: Materials (1996-1944) Type: main |
| ResultId | 1 |
