On the Lack of fusion porosity in L-PBF processes

Lack of fusion porosity is a typical defect of laser powder bed fusion processes generated by a wrong selection of process parameters that do not ensure a proper overlapping of melt pools. Melt pool dimensions and lack of fusion porosity can be predicted using analytical models that use as inputs material properties and process parameters. None of these models considers the variability of the melt pool dimensions in predicting the lack of fusion porosity. In this work, Monte Carlo simulations are used to determine the influence of the variability of the melts pools dimensions on the selection of process parameters