Laser-plume interaction for predictive defect model for multi-laser powder bed fusion additive manufacturing

A system comprising a computer readable storage device readable by the system, tangibly embodying a program having a set of instructions executable by the system to perform the following steps for predicting defects in powder bed fusion additive manufacturing process for a part, the set of instructions comprising:

• an instruction to execute computational fluid dynamics modeling of a gas flow in an additive manufacturing machine manufacturing chamber;
• an instruction to approximate a laser plume relative to a melt pool on a powder bed disposed on a build plate within the manufacturing chamber;
• an instruction to execute space-time analysis to identify a laser plume interaction;
• an instruction to create a plume interaction zone map;
• an instruction to feed the plume interaction zone map prediction into a multi-laser defect model;
• and
• an instruction to predict defect location and density to accumulate lack-of-fusion risk as a function of part placement, orientation, and scan strategy.