Modeling and Validation of Process Parameters for Melt Pool Morphology in LPBF 316L

Laser powder bed fusion (LPBF) enables the production of complex geometries in 316L stainless steel, a material essential for defense, marine, and nuclear applications due to its excellent corrosion resistance and strength. This study examines the influence of LPBF process parameters, particularly laser power and speed, on melt pool morphology and microstructural characteristics in 316L. By varying laser power, it was observed that increased energy input led to larger melt pool width and depth, which in turn affected the microstructure. Specifically, larger melt pools resulted in coarser grain size with strong texture, which can influence mechanical properties and high-temperature thermal stability. Multi-layer, multi-track thermal transient melt pool simulations were conducted to complement the experimental results, revealing the role of cooling rates and thermal gradients in shaping microstructural evolution. These simulations confirmed the experimental trends and provided deep insights into the thermodynamics and solidification of 316L under different LPBF conditions. Through modeling, optimizing LPBF parameters offers a pathway to control microstructural features, ensuring that 316L components meet the stringent performance demands of high-stress, corrosion-resistant environments. This research establishes a foundation for refining LPBF processes to enhance 316L’s material properties, supporting its use in critical applications where strength, durability, and thermal resilience are essential.