Knowing how the process parameters affect the melt pool size is key in additive manufacturing to get a robust and homogeneous build. With the Additive Manufacturing Module in Thermo-Calc, you can simulate the steady state behavior of the melt pool for any material and process parameter. Grange et al. performed a range of single-track experiments on Inconel 738LC with a composition of Ni-15.8 Cr-8.6 Co-2.7 W-3.3 Ti-3.6 Al-1.8 Ta-1.8 Mo-0.04 Fe-0.8 Nb-0.002 Mn-0.1 C Mass % and measured the width and depth of the melt pool.
The single-track experiments with lowest (0.24) and highest (0.47) ratio between Power and scan speed (P/v) were chosen to optimize the parameters for the double ellipsoid heat source, also known as Goldak heat source. Many simulations were run, with varying Heat Source parameters, until good agreement with Grange’s melt pool dimensions were obtained. A linear relation for each Heat source parameter was then applied, as a function of P/v, to simulate all cases in Grange et al.
The comparison between experimental and predicted melt pool sizes are shown in the figures here. As seen, the optimized parameters give a very good agreement between predicted and experimental melt pool dimensions for all process cases, although it was only optimized using 2 of them.