Fitting-Free Diagnosis of Conduction-Model Breakdown in Laser Powder Bed Fusion

Melt-pool depth governs interlayer bonding and porosity in laser powder bed fusion and underpins part qualification, yet predicting it reliably remains difficult. Fast conduction models reach useful accuracy only after the absorptivity is fitted to the depths they are meant to predict, and inverse analyses have been used the same way, to recover a calibrated parameter rather than to test the model. Here, the absorptivity is fixed independently instead, a measured coupling for IN718 and, for IN625 and 316L, a published closed-form relation never fitted to the present depths. This converts a moving-source conduction model from an object of calibration into one of validation. The melt boundary is located by root-finding rather than on a grid, so no discretization error enters the diagnosis. Across 231 single tracks, the model reproduces conduction-regime depth and half-width to within a few percent and underpredicts increasingly once keyholing begins. Inverting each measured depth for the absorptivity conduction would require yielding a fitting-free diagnosis: no conduction-regime track demands a non-physical value, and the inferred value converges near 0.38 against inputs of 0.27 to 0.34, whereas every keyhole-classified track demands a value above unity. Because an inferred absorptivity also absorbs unmodeled transport, downward convection was emulated as an anisotropic effective diffusivity; at the enhancement reported for Marangoni flow, no keyhole track becomes explicable. A measured Ti-6Al-4V absorptivity rise of a factor 1.9 supports the mechanism. An enthalpy-indexed correction and data-driven baselines remain alloy-specific, whereas the physics-based model retains its advantage under cross-alloy extrapolation. All findings are for single tracks on bare plates.