The effect of evaporation and recoil pressure on energy loss and melt pool profile in selective electron beam melting

Powder bed fusion (PBF) systems are the most widely used metal additive manufacturing applications. Among these systems, selective electron beam melting (SEBM) is less common but is preferred for its fast-printing features and manufacturing high-density parts with lower residual stresses and distortion. As with other PBF systems, the predictions of temperature distribution and melt pool dimensions are highly important for this process. In this context, evaporation is also an issue that needs to be focused on due to its effect on the melt pool profile, energy loss, and manufacturing defects. In this study, the effects of evaporation and recoil pressure on the melt pool and energy loss are examined by evaluating experimental solidified melt pool profiles. An empirical recoil pressure expression is derived. A relatively simple but effective modeling approach is presented and validated with experimental results.