In situ process monitoring with respect to mechanical properties of additively manufactured parts

Laser Powder Bed Fusion (LPBF) is governed by intricate interactions between laser settings and material characteristics, which collectively influence melt pool formation, energy absorption, and defect generation. Key parameters such as laser power, scanning speed, beam size, and layer thickness play a critical role in determining the energy absorption behavior and the resulting melting mechanisms. Absorptivity and melt pool depth are especially responsive near the transition between conduction and keyhole melting modes, where thermal properties and energy input become closely linked. The geometry of the melt pool is also affected by the chosen scan strategy and powder properties. Finer and more uniformly distributed powders typically improve energy absorption and promote more stable melt pool formation. This results in higher part density and deeper melt pools across various alloy systems, including titanium, aluminum, and copper. Real-time monitoring technologies, such as infrared pyrometry may allow for dynamic classification of melting regimes during the build process. Furthermore, adjustments in scan strategy can refine thermal behavior and improve part quality. The impact of these parameters varies with material type, highlighting the importance of tailoring process conditions to specific powder characteristics to achieve optimal performance.