Effect of process parameters on solidification microstructure in laser additive manufacturing of Inconel 718 using a new approach of numerical analysis, reverse analysis and experimental design

Effect of process parameters on solidification microstructure in laser additive manufacturing of Inconel 718 using a new approach of numerical analysis, reverse analysis and experimental design | 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 Effect of process parameters on solidification microstructure in laser additive manufacturing of Inconel 718 using a new approach of numerical analysis, reverse analysis and experimental design Mahmoud Afshari, Mehrdad Khandaei, Reza Shoja Razavi, Ali Farzadi, and 1 more This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-7389266/v1 This work is licensed under a CC BY 4.0 License Status: Under Review Version 1 posted 5 You are reading this latest preprint version Abstract In the present work, a novel technique is proposed for simulation of the laser additive manufacturing process to evaluate the final microstructure of Inconel 718. For this purpose, the complex physical phenomena in the process are solved by the equations of steady flow heat transfer, mass transfer, and melting-freezing. The actual laser power was modeled by installing a thermocouple in the sample and by reverse analysis (RA) method. The model was considered as a heat source in the steady simulations. The simulation model was used to calculate the primary dendritic arms spacing (PDAS) at different points of the deposit layer. It was observed that the considered model is in good agreement with the experimental results. An increase in the laser power and a decrease in the scanning speed caused a decrease in the cooling rate and thus an increase in PDAS. With the increase of the powder injection rate, the cooling rate also increased and led to a decrease in the PDAS, although the slope of its changes was greater at higher laser power. Moreover, when the laser power was low (200 W) and scanning speed was high (6 mm/s), a columnar and equiaxed dendrite structure with a short dendritic arm spacing was formed, due to the low temperature gradient and high solidification rate. However, the increase of laser power up to 400 W and the reduction of scanning speed to 2 mm/s led to formation of a cellular and columnar dendritic structure. Volume of fluid (VOF) Reverse analysis Inconel 718 Direct metal deposition (DMD) Primary dendritic arms spacing (PDAS) Full Text Cite Share Download PDF Status: Under Review Version 1 posted Editorial decision: Major Revisions Needed 18 Oct, 2025 Reviewers agreed at journal 29 Aug, 2025 Reviewers invited by journal 29 Aug, 2025 Editor assigned by journal 21 Aug, 2025 First submitted to journal 19 Aug, 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. Our growing team is made up of researchers and industry professionals working together to solve the most critical problems facing scientific publishing. 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-7389266","acceptedTermsAndConditions":true,"allowDirectSubmit":false,"archivedVersions":[],"articleType":"Research Article","associatedPublications":[],"authors":[{"id":507369602,"identity":"41fb1fa4-d5b0-44e8-9d82-f1380f3f1c9d","order_by":0,"name":"Mahmoud Afshari","email":"data:image/png;base64,iVBORw0KGgoAAAANSUhEUgAAAZAAAAAyAQMAAABI0h/eAAAABlBMVEX///8AAABVwtN+AAAACXBIWXMAAA7EAAAOxAGVKw4bAAAA0ElEQVRIiWNgGAWjYJCCD4wNDAxs7A1QLjNhHYwzwFp4DjAwHCBJC4NEAlQLIaDbwPyw8ecOu3w+yddp0h8Y7OQZ2Hkf4NVidoDNsJn3TLJlm3TuNokDDMmGDczsBgS0MJg/ZmxjNmCDaGFOYGBmw+8wswPsHxt/ttUbsEmeBWmpJ0YLj2EDb9thAzYJXpCWw0RoOcxT2MzbdtyAjSd3s8UZg+OGbQS1HG/fCHRYtYF8+9mNNyoqquX5+Y/h14IWccCwImDHKBgFo2AUjAJiAACVwTu47uVs7AAAAABJRU5ErkJggg==","orcid":"","institution":"Malek-Ashtar University of Technology","correspondingAuthor":true,"prefix":"","firstName":"Mahmoud","middleName":"","lastName":"Afshari","suffix":""},{"id":507369603,"identity":"afb08ab9-a65e-4e03-b03d-4997c84385c5","order_by":1,"name":"Mehrdad Khandaei","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Mehrdad","middleName":"","lastName":"Khandaei","suffix":""},{"id":507369604,"identity":"57829169-e36a-499e-a0ad-aee7e427aeca","order_by":2,"name":"Reza Shoja Razavi","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Reza","middleName":"Shoja","lastName":"Razavi","suffix":""},{"id":507369605,"identity":"6466b6e3-4871-4761-99d3-6f9015c18620","order_by":3,"name":"Ali Farzadi","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Ali","middleName":"","lastName":"Farzadi","suffix":""},{"id":507369606,"identity":"e275fb25-da6c-4e08-814f-7fa77bf7d20c","order_by":4,"name":"Masood Barekat","email":"","orcid":"","institution":"","correspondingAuthor":false,"prefix":"","firstName":"Masood","middleName":"","lastName":"Barekat","suffix":""}],"badges":[],"createdAt":"2025-08-16 19:35:43","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-7389266/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-7389266/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":91148309,"identity":"14e89d40-c555-4d86-a47e-07b012608cca","added_by":"auto","created_at":"2025-09-12 06:43:54","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":2790327,"visible":true,"origin":"","legend":"","description":"","filename":"Paperafsharied2.pdf","url":"https://assets-eu.researchsquare.com/files/rs-7389266/v1_covered_6ae28593-3dd7-449f-808f-c55c864cee1a.pdf"}],"financialInterests":"","formattedTitle":"Effect of process parameters on solidification microstructure in laser additive manufacturing of Inconel 718 using a new approach of numerical analysis, reverse analysis and experimental design","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":true,"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":"Volume of fluid (VOF), Reverse analysis, Inconel 718, Direct metal deposition (DMD), Primary dendritic arms spacing (PDAS)","lastPublishedDoi":"10.21203/rs.3.rs-7389266/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-7389266/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eIn the present work, a novel technique is proposed for simulation of the laser additive manufacturing process to evaluate the final microstructure of Inconel 718. 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