Process Parameter Optimization Framework for the Selective Laser Melting of Hastelloy X Alloy Considering Defects and Solidification Crack Occurrence

Recent years have witnessed increasing demand for selective laser melting (SLM) in practical applications; however, determining the appropriate process parameter range remains challenging. In this study, a framework was developed to determine considering occurrence of defects and cracks by conducting single-track test thermal elastoplastic analysis. Keyholing, balling, residual unmelted regions were considered defects. The solidification cracking, which is predominant SLM solution-strengthened Ni-based alloys, considered. Using proposed framework, we could fabricate part with largely no or cracks, except edges, under determined optimal parameters.