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A comprehensive review of recent advances in laser powder bed fusion characteristics modeling: metallurgical and defects

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Abstract

This comprehensive review explores recent advancements in laser powder bed fusion (LPBF) modeling, with a particular focus on metallurgical, temperature, and defect aspects. The study systematically analyzes various modeling methodologies, categorizing them based on characteristics and monitoring approaches. Special attention is given to temperature models, which play a crucial role in capturing the complex thermal dynamics inherent in LPBF processes. Case studies delve into metallurgical modeling, covering aspects such as solidification modes, phase transformations, and morphology. Additionally, the defect analysis section offers a detailed examination of porosity and cracks, highlighting both challenges and advancements in defect mitigation within LPBF. The novelty of this study lies in its meticulous examination of temperature, metallurgical, and defect models, which collectively contribute to a comprehensive understanding of LPBF processes. The application of these models is paramount for optimizing additive manufacturing outcomes. Furthermore, the study not only synthesizes recent trends but also identifies gaps, thus guiding future research endeavors. By emphasizing emerging trends, the review aims to inspire researchers to explore novel avenues, thereby enhancing the applicability of LPBF models. In conclusion, this review consolidates valuable insights, making a significant contribution to the current understanding of LPBF intricacies. Its relevance extends to researchers, practitioners, and enthusiasts in additive manufacturing, providing a foundational resource for ongoing and future investigations.

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  1. School of Mechanical Engineering, Purdue University, 585 Purdue Mall, West Lafayette, IN, 47907, USA

    Seyedeh Fatemeh Nabavi & Hamid Dalir

  2. Toronto, L4J 9E3, Canada

    Anooshiravan Farshidianfar

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Nabavi, S.F., Dalir, H. & Farshidianfar, A. A comprehensive review of recent advances in laser powder bed fusion characteristics modeling: metallurgical and defects. Int J Adv Manuf Technol 132, 2233–2269 (2024). https://doi.org/10.1007/s00170-024-13491-1

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