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 challeng-ing. In this study, a framework was developed to determine the appropriate process parameter range considering the occurrence of defects and cracks by conducting a single-track test and thermal elastoplastic analysis. Keyholing, balling, and the residual unmelted regions were considered de-fects. The occurrence of solidification cracking, which is predominant in the SLM of solution-strengthened Ni-based alloys, was considered. Using the proposed framework, we could fabricate a part with largely no defects or cracks, except for the edges, under the determined optimal process parameters.