Theoretical Analysis of the Process Window for Laser Powder-Bed Fusion for Infrared and Green Lasers Using Rosenthal...

Lack of fusion (LOF) is a dominant defect in Laser Powder-Bed Fusion (PBF-LB/M) caused by insufficient overlapping between adjacent melt pools. This study introduces a rapid, first-principles model based on Rosenthal's analytical solution for a moving point heat source to predict melt pool geometry. Using geometric criteria, the model evaluates whether the melt pool width exceeds the hatching distance and whether the melt pool depth exceeds the layer thickness. Based on these conditions, LOF-based process windows are constructed by plotting laser power against scanning speed and classifying each parameter combination as either LOF or no LOF. The process developed here for constructing LOF process windows can be applied to metallic PBF-LB/M systems. As PBF-LB/M of copper is commonly associated with LOF defects, the approach is examined for pure copper by evaluating a range of laser powers and scanning speeds for both near-infrared (NIR) (1064 nm) and green (515 nm) lasers using copper-specific absorptivity values. The resulting process windows are validated against literature-reported relative density data for pure copper, using high relative density values as indicators of full fusion and lower relative density values reported with LOF characteristics as indicators of lack of fusion. For a 30 µm layer thickness, the predicted LOF boundary agreed with 43 of 46 literature-reported copper PBF-LB/M data points when the data were classified using relative density and reported defect morphology. Sensitivity analysis showed that the agreement changed modestly when the relative-density threshold was reduced from 99% to 98.5% and 98% and that near-boundary classifications were sensitive to the selected absorptivity within the reported NIR range. The agreement supports the use of the framework as a preliminary screening tool for identifying LOF-prone parameter regions. By providing a fast, physics-based screening tool for LOF-limited process windows, this framework offers a computationally efficient alternative to high-fidelity numerical simulations commonly used in PBF-LB/M process development.