SLM: Melt-pool prediction through transient thermal simulation

Abstract

This paper evaluates the accuracy of transient thermal simulations in predicting melt pool geometry, including width and depth, during Selective Laser Melting (SLM) for different laser energy densities (LEDs). While the simulation results show similar trends to experimental data, they exhibit significant accuracy errors, especially at higher LEDs due to the inability to account for keyhole melting caused by the Marangoni effect. Despite these inaccuracies, the simulations remain useful for parameter development if the errors are considered and LEDs that cause keyhole melting are avoided. To achieve more accurate predictions of the melt pool, it is recommended to use a computational fluid dynamics (CFD) approach that includes Marangoni flow and evaporative effects.