As new materials are designed for metal additive manufacturing (AM), there is a need to develop a systematic approach to optimize process parameters. The purpose of this research is to develop a guideline for laser-based powder bed fusion (LPBF) operators that will minimize computational and experimental trial and error. The guideline illustrates a two-step optimization problem based on the following four process parameters: laser power, scan speed, layer thickness, and hatch distance. The first step focuses on optimizing laser power and scan speed parameters in order to achieve desirable melt pool dimensions. The Eagar-Tsai model was employed as an aid to predict the width and depth of the melt pool. The second step optimizes the latter two parameters by considering the melt pool geometry from step one and calculating the optimal hatch distance while mitigating lack of fusion. Characterization of single tracks and cubes is performed to explore the relationship between process parameters and porosity and differential evaporation of a binary nickel alloy
