Experimental and Numerical Study of Single Track Formation in the Laser Powder Bed Fusion Process of AlSi10Mg

Experimental and Numerical Study of Single Track Formation in the Laser Powder Bed Fusion Process of AlSi10Mg | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Research Article Experimental and Numerical Study of Single Track Formation in the Laser Powder Bed Fusion Process of AlSi10Mg Saúl Piedra, Arturo Gómez-Ortega, Christian Félix-Martínez, James Pérez-Barrera This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7818596/v1 This work is licensed under a CC BY 4.0 License Status: Published Journal Publication published 09 Jan, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted 5 You are reading this latest preprint version Abstract This study presents an experimental analysis and computational fluid dynamics (CFD) model for studying single-track formation in the Laser Powder Bed Fusion (LPBF) process, implemented in OpenFOAM. The model incorporates key physical phenomena, including Marangoni convection, recoil pressure, and phase change, to accurately capture melt pool dynamics. A stochastic powder size distribution, statistically characterized from experimental observations, is used as the initial condition to enhance the fidelity of the simulations. AlSi10Mg single-track deposits were performed using a Concept Laser M2 LPBF system, varying laser powers, scan velocities, and spot sizes. Cross-sectional microscopy and porosity analyses revealed transitions from lack-of-fusion to keyhole-induced porosity as a function of volumetric energy density (VED). Numerical results showed good qualitative and quantitative agreement with experimental observations, with relative errors in melt pool dimensions below 12%. Simulations further revealed transient flow patterns and melt pool instabilities difficult to capture experimentally. The findings demonstrate that the combination of experimental observations and simulation tools can be used to construct map process windows, predict defects, and support process optimization in LPBF, understanding the multiphysics phenomena at different building conditions, which is particularly important for high-conductivity aluminum alloys. Laser Powder Bed Fusion CFD simulation Volumetric Energy Density Additive Manufacturing OpenFOAM Aluminum Alloy Full Text Cite Share Download PDF Status: Published Journal Publication published 09 Jan, 2026 Read the published version in The International Journal of Advanced Manufacturing Technology → Version 1 posted Editorial decision: Major Revisions Needed 20 Nov, 2025 Reviewers agreed at journal 10 Oct, 2025 Reviewers invited by journal 10 Oct, 2025 Editor assigned by journal 10 Oct, 2025 First submitted to journal 09 Oct, 2025 You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. As a division of Research Square Company, we’re committed to making research communication faster, fairer, and more useful. We do this by developing innovative software and high quality services for the global research community. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-7818596","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":527726941,"identity":"32b1fc95-91c1-4761-b305-36491244bcf7","order_by":0,"name":"Saúl Piedra","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Saúl","middleName":"","lastName":"Piedra","suffix":""},{"id":527726942,"identity":"e7f15811-ad68-463a-ae6a-9b11dbe4ab8a","order_by":1,"name":"Arturo 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AlSi10Mg","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":false,"highlight":"","institution":"","isAcceptedByJournal":true,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false},"keywords":"Laser Powder Bed Fusion, CFD simulation, Volumetric Energy Density, Additive Manufacturing, OpenFOAM, Aluminum Alloy","lastPublishedDoi":"10.21203/rs.3.rs-7818596/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7818596/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eThis study presents an experimental analysis and computational fluid dynamics (CFD) model for studying single-track formation in the Laser Powder Bed Fusion (LPBF) process, implemented in OpenFOAM. The model incorporates key physical phenomena, including Marangoni convection, recoil pressure, and phase change, to accurately capture melt pool dynamics. A stochastic powder size distribution, statistically characterized from experimental observations, is used as the initial condition to enhance the fidelity of the simulations. AlSi10Mg single-track deposits were performed using a Concept Laser M2 LPBF system, varying laser powers, scan velocities, and spot sizes. Cross-sectional microscopy and porosity analyses revealed transitions from lack-of-fusion to keyhole-induced porosity as a function of volumetric energy density (VED). Numerical results showed good qualitative and quantitative agreement with experimental observations, with relative errors in melt pool dimensions below 12%. Simulations further revealed transient flow patterns and melt pool instabilities difficult to capture experimentally. The findings demonstrate that the combination of experimental observations and simulation tools can be used to construct map process windows, predict defects, and support process optimization in LPBF, understanding the multiphysics phenomena at different building conditions, which is particularly important for high-conductivity aluminum alloys.\u003c/p\u003e","manuscriptTitle":"Experimental and Numerical Study of Single Track Formation in the Laser Powder Bed Fusion Process of AlSi10Mg","msid":"","msnumber":"","nonDraftVersions":[{"code":1,"date":"2025-10-25 19:58:46","doi":"10.21203/rs.3.rs-7818596/v1","editorialEvents":[{"type":"communityComments","content":0},{"type":"decision","content":"Major Revisions Needed","date":"2025-11-20T09:12:03+00:00","index":"","fulltext":""},{"type":"reviewerAgreed","content":"","date":"2025-10-10T16:10:09+00:00","index":0,"fulltext":""},{"type":"reviewersInvited","content":"","date":"2025-10-10T14:11:24+00:00","index":"","fulltext":""},{"type":"editorAssigned","content":"","date":"2025-10-10T12:47:20+00:00","index":"","fulltext":""},{"type":"submitted","content":"The International Journal of Advanced Manufacturing Technology","date":"2025-10-09T10:24:02+00:00","index":"","fulltext":""}],"status":"published","journal":{"display":true,"email":"[email protected]","identity":"the-international-journal-of-advanced-manufacturing-technology","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":false,"externalIdentity":"jamt","sideBox":"Learn more about [The International Journal of Advanced Manufacturing Technology](https://www.springer.com/journal/170)","snPcode":"170","submissionUrl":"https://submission.nature.com/new-submission/170/3","title":"The International Journal of Advanced Manufacturing Technology","twitterHandle":"","acdcEnabled":true,"dfaEnabled":true,"editorialSystem":"em","reportingPortfolio":"Springer Hybrid","inReviewEnabled":true,"inReviewRevisionsEnabled":false}}],"origin":"","ownerIdentity":"accb8a6f-ed73-4e84-9deb-9e941c5a3764","owner":[],"postedDate":"October 25th, 2025","published":true,"recentEditorialEvents":[],"rejectedJournal":[],"revision":"","amendment":"","status":"published-in-journal","subjectAreas":[],"tags":[],"updatedAt":"2026-01-12T16:06:09+00:00","versionOfRecord":{"articleIdentity":"rs-7818596","link":"https://doi.org/10.1007/s00170-025-17344-3","journal":{"identity":"the-international-journal-of-advanced-manufacturing-technology","isVorOnly":false,"title":"The International Journal of Advanced Manufacturing Technology"},"publishedOn":"2026-01-09 15:59:11","publishedOnDateReadable":"January 9th, 2026"},"versionCreatedAt":"2025-10-25 19:58:46","video":"","vorDoi":"10.1007/s00170-025-17344-3","vorDoiUrl":"https://doi.org/10.1007/s00170-025-17344-3","workflowStages":[]},"version":"v1","identity":"rs-7818596","journalConfig":"researchsquare"},"__N_SSP":true},"page":"/article/[identity]/[[...version]]","query":{"redirect":"/article/rs-7818596","identity":"rs-7818596","version":["v1"]},"buildId":"8U1c8b4HqxoKbykW_rLl7","isFallback":false,"isExperimentalCompile":false,"dynamicIds":[84888],"gssp":true,"scriptLoader":[]}