Selective laser melting finite element modeling: Validation with high-speed imaging and lack of fusion defects prediction

Selective laser melting (SLM) is a fast-growing technology which still lacks knowledge and management for wider industrial use. Numerical modeling is today a standard tool in the manufacturing industry to support design and process parameters determination. It is thus of great importance to experimentally validate the simulations in order to ensure their predictive capabilities. However, the fast nature of the process complicates observation of the quantities required for the simulation validation. A finite element model (FEM) of the SLM process is proposed here, together with its numerical validation by comparison with the literature, and experimental validation using high-speed imaging. The melt pool widths and lengths retrieved from the simulation and the videos were measured. The model demonstrated a good accordance with both the literature and the experimental results. Reduced melt pool geometries were simulated in the first tracks which led to lack of fusion defect formations.