Development of an Empirical Model on Melt Pool Variation in Laser Foil Printing Additive Manufacturing Process Using Statistical Analysis

Laser Foil Printing (LFP) is a novel recently developed Additive Manufacturing (AM) process that fabricates components using metal foils in layer-by-layer fashion. LFP has found to perform better than some other well-known AM methods, such as Powder Bed Fusion (LPBF), especially for challenging materials, like aluminum alloys, due the high oxidation level of powders during melting and solidification steps LPBF process. Deployment foil format feedstock alleviates challenges by removing powder material utilization. The properties fabricated parts are be strongly influenced melt pool depths, created laser welding step depths themselves dominated LFP’s parameters, power scan speed. Therefore, correct selection parameter values necessary fabricating with desirable properties. In this work, were various levels speed their measured. By conducting thorough statistical analysis on results, dependency these parameters evaluated. An empirical model also can accurately predict yielding function given per model’s fit experimental results examined validate accuracy predicted results.