Prediction of pore evolution during selected laser melting solidification by a finite element-phase field model

Porosity control in parts built by additive manufacturing is still a great challenge. In this work, we developed a finite element-phase field model to simulate pore evolution during selected laser melting solidification, and focused on the effects of energy density on the porosity. The model reproduced the solidification phenomena observed experimentally and revealed the quantitative relation between porosity and energy density. It was found that the critical energy density of Ti-6Al-4V alloy for full densification is 45 J/mm^3 to 75 J/mm^3, which is in good accord with the experimental results.