Investigating the melt pool properties and thermal effects of multi-laser diode area melting

Diode area melting (DAM) is a new additive manufacturing process that utilises customised architectural arrays of low-power laser diode emitters for high-speed parallel processing of metallic feedstock. The laser diodes operate at shorter laser wavelengths (808 nm) than conventional SLM fibre lasers (1064 nm) theoretically enabling more efficient energy absorption for specific materials. This investigation presents the first work investigating the melt pool properties and thermal effects of the multi-laser DAM process, modelling generated melt pools the unique thermal profiles created along a powder bed during processing. Using this approach process, optimisation can be improved by analysing this thermal temperature distribution, targeting processing conditions that induce full melting for variable powder layer thicknesses. In this work, the developed thermal model simulates the DAM processing of 316L stainless steel and is validated with experimental trials. The simulation indicates that multi-laser DAM methodology can reduce residual stress formation compared to the single point laser scanning methods used during selective laser melting.