Achievement of a Parameter Window for the Selective Laser Melting Formation of a GH3625 Alloy

In the selective laser melting (SLM) process, adjusting process parameters contributes to achieving the desired molten pool morphology, thereby enhancing the mechanical properties and dimensional accuracy of manufactured components. The parameter window characterizing the relationship between molten pool morphology and process parameters serves as an effective tool to improve SLM's forming quality. This work established a mesoscale model of the SLM process for a GH3625 alloy based on the discrete element method (DEM) and computational fluid dynamics (CFD) to simulate the forming process of a single molten track. Subsequently, the formation mechanism and evolution process of the molten pool were revealed. The effects of laser power and scanning speed on the molten pool size and molten track morphology were analyzed. Finally, a parameter window was established from the simulation results. The results indicated that reducing the scanning speed and increasing the laser power would lead to an increase in molten pool depth and width, resulting in the formation of an uneven width in the molten track. Moreover, accelerating the scanning speed and decreasing the laser power cause a reduction in molten pool depth and width, causing narrow and discontinuous molten tracks. The accuracy of the simulation was validated by comparing experimental and simulated molten pool sizes.