Methods of optimizing 3-D printing parameters for metallic materials

A system, comprising:

• a laser powder bed fusion printer;
• a processor;
• and
• a memory coupled to the processor, wherein the memory stores instructions which when executed by the processor cause the system to:
• perform a simulation of melt pool temperature and melt pool geometries for an alloy at a plurality of combinations of a laser speed parameter and a laser power parameter;
• create an initial printability map based on the laser speed parameter and the laser power parameter based on the simulation of melt pool temperature and melt pool geometries;
• define, within the printability map, one or more regions of the printability map that correspond to one or more manufacturing defects;
• sample the printability map to determine a plurality of samples within the printability map, wherein each sample comprises a value of the laser speed parameter and a value of the laser power parameter;
• print, using the laser powder bed fusion printer, a plurality of sample tracks corresponding to the plurality of samples;
• perform a set of single-track experiments on the plurality of sample tracks to corresponding to the plurality of samples;
• calibrate the printability map based on the set of single-track experiments to create a revised printability map;
• generate a plurality of hatch spacing contours based on a geometric criterion, wherein the plurality of hatch spacing contours define a spacing between adjacent beads in a three-dimensional printed part;
• add the plurality of hatch spacing contours to the revised printability map to create a final printability map, wherein the final printability map represents a printability characteristic of the alloy at a plurality of combinations of laser speed, laser power, and hatch spacing;
• fabricate a bulk sample of the alloy using the laser powder bed fusion printer, wherein the laser powder bed fusion printer is configured-based on the finalized printability map;
• measure a bulk sample property of the bulk sample;
• identify an optimal combination of processing parameters based on the bulk sample property of the bulk sample;
• configure the laser powder bed fusion printer to print the defect-free metal part using the optimal combination of processing parameters, wherein the optimal combination of processing parameters comprise laser speed, laser power, and hatch spacing;
• and
• print, using the laser powder bed fusion printer, the defect-free metal part using a combination of laser speed, laser power, and hatch spacing selected from the plurality of combinations of laser speed, laser power, and hatch spacing of the printability map to operate the laser powder bed fusion printer with the optimal combination of laser speed, laser power, and hatch spacing.