Parameter optimization for metal powders in Selective Laser Melting (SLM) is usually
carried out by experimental investigations of the influence of significant parameters (such as laser
power, scan speed, hatch spacing, layer thickness, scan pattern, etc.) on microstructure and/or
mechanical properties. This type of experimental optimization is extremely time- and cost-consuming. In order to accelerate the optimization process, a study was undertaken to develop a
method for rapid optimization of parameters based on melt pool characterizations. These
characterizations began with investigations of SLM single bead experiments. Pre-alloyed Ti-6Al-4V powder was used for single bead fabrication with multiple laser power and scan speed
combinations. Surface morphology and dimensions of single beads were characterized.
Geometrical features of melt pools were measured after polishing and etching of the cross section
of each single bead. It was found that melt pool characteristics provide significant information that
is helpful for process parameters selection. These experiments are being extended to characterize
test pads with multiple layers.Mechanical Engineerin
