Effect of processing parameters on thermal behavior and related density in GH3536 alloy manufactured by selective laser melting

GH3536 alloy is one of the high-temperature nickel-based alloys and widely applied in aviation and aerospace industries. In this study, a combination of experiment and simulation is proposed to study the effect of processing parameters on the selective laser melting (SLM) of GH3536 powder. It is concluded that the relationship between density and laser input energy during SLM complies with a quadratic function and presents an inverted U-shaped distribution. By fitting density and input power to a quadratic polynomial, the optimal laser input energy during SLM of GH3536 alloy can be obtained. The result shows that using 275 W laser power and 960 mm/s scanning speed, the SLM GH3536 specimens can reach the maximum density. This experimental result is consistent with the simulation result obtained by analyzing molten pool dimension. Furthermore, a full process energy prediction diagram for SLM GH3536 alloy based on the simulated molten pool depth and width is proposed. The result shows that it provides an innovative and efficient method for the selection of processing parameters during SLM of GH3536 powder.