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<p>This study examines the influence of selective laser melting process parameters, viz. scan power (120–400 W), scan speed (300–1400&#xa0;mm/s), and hatch distance (0.0463–0.1544&#xa0;mm) on the solidification dynamics and microstructural characteristics of IN718, utilizing a novel Non-Dimensional Heat Input (NDHI) parameter. NDHI incorporates both material properties and process variables, providing a systematic framework for analyzing their interactions. The relationship between NDHI, process parameters, melt pool geometry, and microhardness has been established and has been experimentally validated through optical and scanning electron microscopy. A detailed understanding of melt pool formation mechanisms, particularly the roles of recoil pressure and Marangoni convection, was established and aligned with the microstructural features and melt pool profiles. Furthermore, the transition from conduction to keyhole mode was validated through enthalpy-based criteria and correlated with changes in melt pool geometry. The NDHI was found effective in representing microstructural features, melt pool geometry, microhardness with optimal performance observed at NDHI = 2.7175, scan power = 280 W, scan speed = 960&#xa0;mm/s, and hatch spacing = 0.1081&#xa0;mm. The findings highlight the potential of NDHI as a robust parameter for understanding the complex microstructural evolution and mechanical properties in Selective Laser Melting (SLM) processed IN718. These insights contribute to the optimization of additive manufacturing process parameters, enabling enhanced performance of IN718 components in advanced engineering applications.</p>

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Effect of Print Parameters on the Microstructural Evolution in Additively Manufactured In718: Experimental Studies and Analytical Formulation

  • 期刊论文

  • 发表日期：

    2025年9月29日

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  • M. N. Nazeemudheen,
  • Sushant Manwatkar,
  • S. V. S. Narayana Murty,
  • Srinu Gangolu

摘要

This study examines the influence of selective laser melting process parameters, viz. scan power (120–400 W), scan speed (300–1400 mm/s), and hatch distance (0.0463–0.1544 mm) on the solidification dynamics and microstructural characteristics of IN718, utilizing a novel Non-Dimensional Heat Input (NDHI) parameter. NDHI incorporates both material properties and process variables, providing a systematic framework for analyzing their interactions. The relationship between NDHI, process parameters, melt pool geometry, and microhardness has been established and has been experimentally validated through optical and scanning electron microscopy. A detailed understanding of melt pool formation mechanisms, particularly the roles of recoil pressure and Marangoni convection, was established and aligned with the microstructural features and melt pool profiles. Furthermore, the transition from conduction to keyhole mode was validated through enthalpy-based criteria and correlated with changes in melt pool geometry. The NDHI was found effective in representing microstructural features, melt pool geometry, microhardness with optimal performance observed at NDHI = 2.7175, scan power = 280 W, scan speed = 960 mm/s, and hatch spacing = 0.1081 mm. The findings highlight the potential of NDHI as a robust parameter for understanding the complex microstructural evolution and mechanical properties in Selective Laser Melting (SLM) processed IN718. These insights contribute to the optimization of additive manufacturing process parameters, enabling enhanced performance of IN718 components in advanced engineering applications.