Sensitivity Analysis in the Thermal History of Metal Laser Powder Bed Fusion Additive Manufacturing Using HYPAD-FEM

Additive manufacturing (AM) is transforming global manufacturing by offering design flexibility and rapid innovation through layer-by-layer part production. It is gaining importance in industrial production due to metals' crucial role in modern manufacturing. Laser powder bed fusion (LPBF) is the most mature and widely used metal-based AM technology, known for producing complex, accurate, and large parts with improved surface quality. [Figure] Challenges in Laser Powder Bed Fusion Additive Manufacturing: LPBF utilizes high-speed and high-power lasers, but this can result in undesirable microstructural traits and mesoscale defects that impact mechanical performance. [Figure] Analyzing the thermal profile of PBF AM is critical for improving the quality, reliability, and efficiency of the process, as well as for advancing our understanding of the underlying physics and facilitating its broader adoption in industrial applications. [...]