Effect of laser power and focal spot size on the performance of LPBF systems

Laser Powder Bed Fusion (LPBF) technologies are now being widely adopted across the global industrial landscape. New LPBF systems with multiple lasers and an expanded work area are entering the market, thereby enhancing both the production speed and the maximum size of 3D parts that can be produced. The aim was to investigate the aspects of upscaling LPBF processing parameters on the characteristic formation of stable single tracks, which are the primary building blocks for this technology. A number of LPBF systems were employed in this study, each operating independently and utilizing distinct parameter regimes, to produce the single tracks on a solid substrate deposited with a thin powder layer. The results demonstrated that the geometrical characteristics of single tracks are predominantly influenced by laser power and scanning speed when scanning a thin powder layer. The results also indicate that higher laser power and spot size can be used to produce stable tracks with increasing linear energy input. However, there are a number of nuances to be considered in increasing the performance.