Enhanced Mathematical Model for Producing Highly Dense Metallic Components through Selective Laser Melting

In this work, a previously developed mathematical model to predict bulk density of SLMed (produced via Selective Laser Melting) component is enhanced by taking laser power, scanning speed, hatch spacing, powder's thermal conductivity and specific heat capacity as independent variables. Experimental data and manufacturing conditions for the selective laser melting (SLM) of metallic materials (which include aluminum, steel, titanium, copper, tungsten and nickel alloys) are adapted from the literature and used to evaluate the validity of the proposed enhanced model. A strong relation between dependent and independent dimensionless products is observed throughout the studied materials. The proposed enhanced mathematical model shows to be highly accurate since the computed root-mean-square-error values (RMSE) does not exceed 5 × 10^-7. Furthermore, an analytical expression for the prediction of bulk density of SLMed components was developed. From this, an expression for determining the needed scanning speed, with respect to laser power, to achieve highly dense components produced via SLM, is derived.