Selective Melting Research Articles

Development of High-Silica Adakitic Intrusions in the Northern Appalachians of New Brunswick (Canada), and Their Correlation with Slab Break-Off: Insights into the Formation of Fertile Cu-Au-Mo Porphyry Systems

High-silica adakites exhibit specific compositions, as follows: SiO2 ≥ 56 wt.%, Al2O3 ≥ 15 wt.%, Y ≤ 18 ppm, Yb ≤ 1.9 ppm, K2O/Na2O ≥ 1, MgO < 3 wt.%, high Sr/Y (≥10), and La/Yb (>10). Devonian I-type adakitic granitoids in the northern Appalachians of New Brunswick (NB, Canada) share geochemical signatures of adakites elsewhere, i.e., SiO2 ≥ 66.46 wt.%, Al2O3 > 15.47 wt.%, Y ≤ 22 ppm, Yb ≤ 2 ppm, K2O/Na2O > 1, MgO < 3 wt.%, Sr/Y ≥ 33 to 50, and La/Yb > 10. Remarkably, adakitic intrusions in NB, including the Blue Mountain Granodiorite Suite, Nicholas Denys, Sugar Loaf, Squaw Cap, North Dungarvan River, Magaguadavic Granite, Hampstead Granite, Tower Hill, Watson Brook Granodiorite, Rivière-Verte Porphyry, Eagle Lake Granite, Evandale Granodiorite, North Pole Stream Suite, and the McKenzie Gulch porphyry dykes all have associated Cu mineralization, similar to the Middle Devonian Cu porphyry intrusions in Mines Gaspé, Québec. Trace element data support the connection between adakite formation and slab break-off, a mechanism influencing fertility and generation of porphyry Cu systems. These adakitic rocks in NB are oxidized, and are relatively enriched in large ion lithophile elements, like Cs, Rb, Ba, and Pb, and depleted in some high field strength elements, like Y, Nb, Ta, P, and Ti; they also have Sr/Y ≥ 33 to 50, Nb/Y > 0.4, Ta/Yb > 0.3, La/Yb > 10, Ta/Yb > 0.3, Sm/Yb > 2.5, Gd/Yb > 2.0, Nb + Y < 60 ppm, and Ta + Yb < 6 ppm. These geochemical indicators point to failure of a subducting oceanic slab (slab rollback to slab break-off) in the terminal stages of subduction, as the generator of post-collisional granitoid magmatism. The break-off and separation of a dense subducted oceanic plate segment leads to upwelling asthenosphere, heat advection, and selective partial melting of the descending oceanic slab (adakite) and (or) suprasubduction zone lithospheric mantle. The resulting silica-rich adakitic magmas ascend through thickened mantle lithosphere, with minimal affect from the asthenosphere. The critical roles of transpression and transtension are highlighted in facilitating the ascent and emplacement of these fertile adakitic magmas in postsubduction zone settings.

Oxygen-rich combustion behaviors and mechanisms of a new Ni-Cr-based superalloy fabricated by selective laser melting

The mechanical and combustion behavior of a new Ni-Cr-based superalloy, fabricated by selective laser melting in an atmosphere with an oxygen concentration greater than 99.5 %, was investigated through the analysis of microstructural morphology, elements distribution and combustion kinetics. The results show that heat treatment eliminated the anisotropy of the as-built microstructures and improved the tensile strength. The studied superalloy can be ignited with a combustion threshold of about 2.5 MPa–3 MPa. The burning length and burning rate increase with the increase of pressure. The selective combustion of Al, Ti, Nb, Cr, Fe, Mo, and Cu elements occurred, resulting in the dissolution of γ′, γ", and δ precipitates and formation of holes at the grain boundaries in the heat-affected zone. The microstructures exhibit large elongated grains in the melting zone and column grains in the heat-affected zone along the heat dissipation direction. The combustion products are a mixture of oxides exhibiting dendritic structures in terms of selective combustion, density, and melting point. The findings from this study enhance our comprehension of the combustion process in nickel-based superalloys, offering valuable data and guidance for the advancement of new oxygen-rich combustion-resistant superalloys.

Numerical Study of Temperature Field and Melt Pool Properties during Electron Beam Selective Melting Process with Single Line and Multiple Line Scanning

Numerical Study of Temperature Field and Melt Pool Properties during Electron Beam Selective Melting Process with Single Line and Multiple Line Scanning

Introduction of the Experimental Setup for the Investigation of the Novel Selective Melt Dispersion (SMD): A Directed Energy Deposition (DED) Process

This study focuses on developing an experimental setup to investigate the Selective Melt Dispersion (SMD), a Directed Energy Deposition (DED) process. SMD as a means of in-process joining (IPJ) aims to integrate components and assemblies during additive manufacturing, combining the advantages of various processes for eco-friendly and economical resource utilization. The research initially analyzed DED systems and defined requirements for subsystems and the overall system. Critical subsystems, including the energy source, material feed, and others, were sequentially developed, and a proof of concept involved building 20 stacked welded tracks, validated through micrograph analysis. The study concludes by evaluating and discussing the fulfillment of the defined requirements. The system comprises a centrally arranged vibration-assisted powder feed; a laterally arranged laser incidence at a 45° angle; a kinematic structure where all axes are arranged on the workpiece, so the powder supply does not require movement; and a shield gas supply.

TiAl Alloy Fabricated Using Election Beam Selective Melting: Process, Microstructure, and Tensile Performance

TiAl alloy is one of the most attractive candidates for a new generation of high-temperature structural materials and has broad application prospects in the aerospace field. As a typical intermetallic material, TiAl is inevitably difficult to process using conventional methods. Election beam selective melting (EBSM) is an effective method of addictive manufacturing to prepare TiAl alloy with a complex structure. However, the microstructure of TiAl alloy formed using EBSM often contains defects such as pores, which seriously reduces the mechanical properties of the material. In this work, the effects of EBSM and post-processing procedures on the microstructure and mechanical properties of Ti-48Al-2Cr-2Nb alloy were studied. The results show that the microstructure of Ti-48Al-2Cr-2Nb alloy formed using the EBSM process was dense and composed of equiaxed γ-phase and double-phase regions. A large number of dislocations that formed due to thermal stress were clearly observed inside the Ti-48Al-2Cr-2Nb alloy. When the EBSM process parameters were 13.5 mA, 4.0 m/s, and 40.50 J/mm3, as the current intensity increased, the Al content decreased, the content of α2 phase increased, and the microstructure of the material was coarse. The results of the tensile test fracture morphology indicate that the Ti-48Al-2Cr-2Nb alloy exhibited brittle fracture during tensile deformation, lacking the typical yield deformation of metal materials. As the energy density of the EBSM process increased, the mechanical properties of the Ti-48Al-2Cr-2Nb alloy first increased and then decreased. The samples prepared with an energy density of 34.50~40.50 J/mm3 had excellent mechanical properties, of which the maximum tensile strength and maximum elongation reached 643 MPa and 2.09%, respectively. The phase composition of the Ti-48Al-2Cr-2Nb alloy after hot isostatic pressing (HIP) treatment remained unchanged from the EBSM samples, but there was a slight difference in content. There was an increase in the amount of γ phase and a decrease in B2 phase, accompanied by the generation of a massive γ phase after HIP treatment. Moreover, the number of dislocations inside the material increased. The Ti-48Al-2Cr-2Nb alloy after HIP treatment exhibited obvious plastic deformation characteristics, with a tensile strength of 679 MPa and elongation of 2.5%. A heat treatment of 900 °C/5 h was performed on the Ti-48Al-2Cr-2Nb alloy after HIP. The dislocation density of the Ti-48Al-2Cr-2Nb alloy decreased, and the B2 phase transformed from massive to lamellar.

High temperature stability of entropy-stabilized oxide (MgCoNiCuZn)0.2O in air

Entropy-stabilized oxides are single-phase, multicomponent oxides that are stabilized by a large entropy of mixing, ΔS, overcoming a positive enthalpy. Due to the −TΔS term in the Gibbs' free energy, G, it can be hypothesized that entropy-stabilized oxides demonstrate a robust thermal stability. Here, we investigate the high temperature stability (1300–1700 °C) of the prototypical entropy-stabilized rocksalt oxide (MgCoNiCuZn)0.2O in air. We find that at temperatures >1300 °C, the material gradually loses Cu and Zn with increasing temperature. Cu is lost through a selective melting as a Cu-rich liquid phase is formed. Zn is sublimed from the rocksalt phase at approximately similar temperatures to those corresponding to the Cu loss, significantly below both the melting temperature of ZnO and its solubility limit in a rocksalt phase. The elemental loss progressively reduces the entropy of mixing and results in a multiphase solid upon quenching to room temperature. We posit that the high-temperature solubility of Cu and Zn is correlated providing further evidence for entropic stabilization over general solubility arguments.

Effect of graphite content on the microstructure and mechanical properties of SLS-based RB-SiC ceramics

In this study, reactive bonded (RB)-SiC ceramics were fabricated using a combination of selective laser sintering (SLS) and reactive melt infiltration (RMI). The microstructure and mechanical properties of RB-SiC ceramics were optimized by adjusting the graphite content. The sintered bodies were found to consist of α-SiC, β-SiC, Si and C. The addition of graphite prolonged the reaction time between carbon and silicon, resulting in a greater infiltration of molten silicon and an increased formation of β-SiC. Furthermore, a correlation was observed between the proportion of graphite content and the bulk density and bending strength of RB-SiC ceramics. In the range of 0–10 wt%, the bulk density initially increased and then decreased as the graphite content increased. The maximum density was found to be 2.74 ± 0.15 g/cm3. The flexural strength reached the maximum value at 217.9 ± 16.9 MPa when the graphite content was 5 wt%. However, beyond this point, the flexural strength decreased rapidly. The present research demonstrates the promising potential of utilizing SLS additive manufacturing to fabricate SiC ceramics with exceptional mechanical properties.

Anomalous strain rate dependence of ultra-low temperature strength and ductility of an electron beam additively manufactured near alpha titanium alloy

The strain rate (ε˙) dependence of ultra-low temperature strength and ductility was investigated systematically on a cryogenic near alpha titanium alloy Ti-3Al-3Mo-3Zr-0.2Y additively manufactured by electron beam selective melting (EBSM). As ε˙ increases under quasi-static tension at 77 and 20 K, ductility monotonically decreases when yield strength (YS) keeps ascending. As ε˙ increases from 5.6 × 10–4 s−1 once by one order of magnitude, elongation-to-fracture declines from 20.0 % to 16.5 % and 15.7 % at 20 K. However, unlike the regular monotone increase at 298 and 77 K, ultimate tensile strength (UTS) at 20 K rises to 1460 MPa first then drops to 1320 MPa. This study further examined how strain rate affects slipping, twinning and strain hardening behavior. The monotone increase in YS is primarily attributed to the increased CRSS for slips and the enhanced tendency of pyramidal 〈a〉 and 〈c + a〉 slipping and <101¯0 > 34° twinning at 20 K. On the other hand, the monotone decrease of ductility is essentially ascribed to the intensified deformation localization characterized by micro shear bands, multiple necking and single necking. More importantly, the mechanisms of abnormal UTS variation and disappearance of serration flow at 20 K are discussed in terms of strain hardening levels, degree of shear deformation localization and the interaction of slips and twins. This study provides deep insights into strain rate effect on cryogenic mechanical behavior of EBSM-built titanium alloy.

Multi-scale numerical simulation of the thermodynamic characteristics of Nb particles reinforced Zr-based amorphous composites by SLM

Room temperature brittleness is a critical factor that restricts the use of amorphous alloys. The approach taken involves the creation of amorphous composite materials by incorporating a second phase, aiming to overcome this critical challenge. This study established a comprehensive three-dimensional transient finite volume model to explore the process of producing niobium particles reinforced zirconium based amorphous alloys using laser selective melting technology. The model comprehensively considered physical transformations, including melting, wetting, spreading, and solidification of powder materials under laser irradiation, along with gravitational effects, surface tension, and evaporation recoil pressure. The investigation delved into the thermal effects and thermodynamic behavior of molten pool across composite material at multi-scales. The results showed that, when using a laser power of 90 W and a scanning speed of 1 m/s, Nb particles were partially melted or remain unmelted. These particles may exist in the molten pool’s pores, enhancing the plasticity of amorphous materials. As laser power and scanning speed increased, defects such as sputtering and spheroidization emerge in the composite molten pool. The control of forming parameters could mitigate these defects. Importantly, the simulation results aligned well with experimental outcomes, bolstering the reliability and applicability of the finding. At the same time, the addition of Nb particles improved the plasticity of amorphous alloys.

Sound absorption performance of a micro-perforated plate sandwich structure based on selective laser melting

ABSTRACT This study proposes a sandwich structure of triply periodic minimal surface (TPMS) based on the theory of micro-perforated plates. This structure was processed using laser selective melting (SLM) with the acoustic-vibration theoretical model established through the acoustic-electrical analogy method. The theoretical model was verified by comparison with the experimental results, showing that the micro-perforated plate TPMS sandwich structure exhibited good sound absorption performance with the maximum sound absorption coefficients being higher than 0.8. The micro-perforated plate TPMS sandwich resonated when excited by sound waves. The change in the volume fraction affected the size of the cavity volume behind the micro-perforated plate, thereby affecting the resonance frequency. The increase in volume fraction decreased the volume of the cavity behind the structural plate, the sound absorption performance to increase, the resonance frequency to move towards high frequencies, and the sound absorption bandwidth to decrease. The resonance frequency was negatively correlated with the panel thickness. The increase in the panel thickness increased the maximum sound absorption coefficient and decreased the sound absorption bandwidth when the structure resonated. Also, high-order resonance frequencies appeared when the number of cell layers increased to a certain level.

Biomimetic dental implant production using selective laser powder bed fusion melting: In-vitro results

Instead of a textured surface with irregular pore size and distribution as in conventional dental implants, the use of lattice structures with regular geometric structure and controlled pore size produced by selective laser powder bed fusion melting (LPDF) technique will provide more predictable and successful results regarding osseointegration and mechanics. In this study, biomimetic dental implants with 2 different pore designs were fabricated by LPDF technique and compared with conventional dental implants in terms of surface characterization and resistance to biomechanical forces. Finite element analysis, scanning electron microscopy, computed micro tomography scanning, ISO 14801 tests and detork tests were used for the comparison. The tested biomimetic implants were found to be as durable as conventional implants in terms of mechanical strength and detork values. They were also found to be 40–60% more advantageous than conventional dental implants with respect to surface area and volume. As a result, it was concluded that biomimetic dental implants with sufficient mechanical strength and complex surface geometries can be made as designed without changing the reliable base material and can be produced using a different manufacturing method.

Effects of different treatment processes on microstructure and tensile fracture behaviour of selected laser melting TC17 titanium alloy

It is essential to study the tensile fracture mechanism of additively manufactured materials and develop the effective process treatment techniques to improve their fracture resistance. In this paper, the effects of different treatment processes on the microstructure and tensile fracture properties of TC17 titanium alloy melted by laser selective zone melting were investigated. The static tensile fracture morphological characteristics were observed by combining SEM and EDS. The metallographic microstructure after chemical corrosion was observed optically. And the tensile fracture morphology of the three states of TC17 titanium alloy samples at room temperature conditions was investigated. The results show that the metallographic matrix microstructure of TC17 titanium alloy after HT, HIP and HIP-HT treatments was a bimodal structure with α+β phases, i.e., β phase was in the form of a net basket, and α phase was in the form of a coarse bar. The grain sizes of the samples treated by different processes were different, but the difference in grain size of the HT-treated tissues was small, and the difference in grain size of the HIP-HT-treated tissues was large. And the coarse α-phase segregation could be seen at the edge of the samples. The 3D-printed materials had complex changes in anisotropic properties affected by the printing structure and tissue. The printed tissues were brittle and had high internal stresses. These problems were partly improved at high temperatures, but they still existed. The HIP-HT-treated materials had a large α+β-phase bimodal structure. The HT-treated material had coarse grains and precipitation phases, poor room temperature plasticity, and improved high temperature plasticity. After HT treatment, the original printing microstructure changed, the strength and plasticity were significantly improved, but the macroscopic printing structure still had a slight influence on the fracture morphology. When HIP treatment temperature was higher, the influence of macroscopic printing structure basically disappeared, but the grain and microstructure grew up, and the strength and plasticity were slightly lower than that of the HT treatment. HIP process basically eliminated the unfused defects of the three-dimensional morphology, and the local weak bonding zone formed.

Defect and Quality Control of GH3536 Super Alloy Fabricated via Laser Selective Melting

Defect and Quality Control of GH3536 Super Alloy Fabricated via Laser Selective Melting

Powder sintering kinetics during electron beam based additive manufacturing

Electron Beam Powder Bed Fusion (PBF-EB) allows not only for the additive manufacturing of fully dense metallic components via melting but also parts with defined local pore structures and tailored functional properties through selective sintering. The hybrid PBF-EB technology based on the combination of selective sintering and melting is, e.g., of great interest for the fabrication of porous electrodes composed of titanium-based alloys with high specific surface area, which are widely used for electrochemical processes (e.g., as anode for water electrolysis cells). This study aims to provide a comprehensive understanding of the sintering kinetics of Ti6Al4V (especially in the first and second sintering stages) during PBF-EB. The sintering degrees of the PBF-EB-processed Ti6Al4V samples are characterized by determining the thermal diffusivity measured by laser flash analysis. At the same time, the thermal history during PBF-EB is analyzed using a pyrometer. The correlation between the sintering degrees and the process parameters utilized in the PBF-EB procedure is discussed by calculating the activation energy of sintering and described using a master sintering curve. Based on the findings of this study, it is possible to control the sintering process of Ti6Al4V powder in a targeted manner by utilizing various PBF-EB parameters.

Optimization of process parameters effects on mechanical properties of selective laser melted iron samples

AbstractSelective laser melting is an additive manufacturing technology whereby parts are built through selective melt of a powder bed by a laser beam. This technology is used to produce net shape parts in 3D printers. In this study, the effect of selective laser melting parameters on the mechanical properties (ultimate tensile strength and hardness) of iron has been experimentally extracted, and the optimum levels of the parameters have been determined for optimum mechanical properties using signal‐to‐noise analysis. The selected parameters include the laser power, the laser scanning speed, and the laser hatch distance, and the design of experiments was done by the Taguchi method. The main effects of factors and interactions were considered in this paper. The results show that the optimum parameter levels for the ultimate tensile strength include the laser power of 200 W, the laser scanning speed of 600 mm/s, and the hatch distance of 70 μm. The optimal parameters for hardness are similar to the maximum tensile strength, except that the optimum hatch distance is 60 μm.

Impact-related chemical modifications of the Chang’E-5 lunar regolith

Impact events on the Moon have been recognized as modifying the composition of surface materials through processes such as shock metamorphism and mixing with exotic components. Previous studies have indicated that the regolith sampled by the Chinese Chang’E-5 mission was primarily evolved from local mare basalts, likely originating from a single episode of effusive volcanism. The relatively simple and monotonic protolith of the Chang’E-5 regolith presents a unique opportunity to investigate the chemical modifications induced by impact events. In this study, we conducted detailed petrographic and mineralogical analyses on a diverse set of lunar regolith samples, including thirty-three small impact glass particles (39–227 μm), one large agglutinate (∼1.6 mm), and sixteen basaltic clasts (0.1–1.6 mm). Numerical modeling was also conducted to quantitatively assess the melting behavior of basaltic clasts under different impact conditions. Our primary objective was to evaluate the chemical variations of impact glass in relation to lithic clasts. While the majority of homogeneous impact glass spherules and larger basaltic clasts (≥1 mm) exhibit similar bulk compositions (e.g., Al2O3, CaO and FeO) to the local regolith, we recognize additional effects of impact processes, including impact comminution, impact melting and crystallization, differential volatilization, and potentially selective melting. These processes have modified the texture and geochemistry of lunar regolith components. The chemical signatures of small clasts in the Chang’E-5 regolith indicate that the fine size fractions (e.g., those with diameters of ≤ 300 μm) are predominantly composed of lithic and monomineralic fragments with a substantial proportion being dominated by mesostasis. Melting of these sub-millimeter fractions may lead to the formation of impact glass with chemical compositions deviating from the average local regolith. These results have implications for understanding the compositional evolution of the Chang’E-5 regolith. Notably, our study suggests that impact glasses spherules with different major (e.g., TiO2, MgO) and minor (e.g., REEs, Zr, Th and U) element compositions could be derived from the same protolith of local mare basalts, instead of being exclusively attributed to exotic impact ejecta. In this case, small-scale local impacts may have played a crucial role in the impact history of the Chang'E-5 landing site.

Tensile properties of Ti6.5Al2Zr1Mo1V titanium alloy fabricated via electron beam selective melting at high temperature

Here, near α titanium alloy TA15 (Ti-6.5Al–2Zr–1Mo–1V) samples were fabricated by electron beam selective melting (EBSM) and their high-temperature tensile deformation behaviors were studied at 773K–1023K. The results show that the tensile strength decreases gradually with the deformation temperature while the yield ratio increases as temperature increases from 773K to 923K, and then decreases gradually with further increasing the temperature. The deformation mechanism of EBSM-built TA15 samples at elevated temperatures can be ascribed to work hardening caused by the increase of dislocation density, and softening caused by the recovery and recrystallization. The studied TA15 alloy exhibits obvious work hardening behaviors at both 773K and 823K, dynamic recovery occurs during tensile deformation at 873K, and dynamic recrystallization plays a dominant role at 923K–1023K. The EBSM-built TA15 samples have excellent mechanical properties at medium temperatures, and the present results are helpful for the industrial applications of EBSM-built titanium alloy components in the aerospace fields.

Optimization of Sandblasting to Improve the Surface Finish of 17-4PH Parts Manufactured by SLM Using Different Laser Scanning Strategies

Great advances have emerged in recent years around additive manufacturing techniques, with an increasing number of different materials (polymers, ceramics, metals). However, metal part manufacturing has always been one of the most demanded in engineering. That is due to its ability to create final functional parts with good mechanical properties. One of the most widely used technique is Selective Laser Melting (SLM). The SLM process uses a laser power source to selectively melt metal powder layer by layer. Typically, this manufacturing technique requires mechanical post-processing operations, not only to split the parts from the build-plate, but also to improve the mechanical properties and surface finish of parts or the dimensional accuracy of specific regions to ensure assembly and interchangeability. In particular, sandblasting is a method of mechanical abrasion cleaning commonly used and very useful for improving the surface topology of SLM printed parts. Besides, the laser scanning strategy used in this additive manufacturing process influences the surface quality of parts. Therefore, in this work, the sandblasting post-process has been optimized for surface roughness improving in parts printed using the most common laser scanning strategies (normal, hexagonal, concentric). The role that sandblasting pressure and time plays in the surface quality of parts, indispensable to optimize this SLM post-process, has been evaluated. Thus, surface roughness of different specimens subjected to different sandblasting parameters has been measured to optimize both values related to the laser scanning strategy used in SLM manufacturing. The material used is 17-4PH stainless steel, an alloy that presents an excellent combination of high strength and good corrosion resistance, high hardness, good thermal properties, as well as excellent mechanical properties at high temperatures. This precipitation-hardened steel has important applications in the aerospace sector, chemical and petrochemical industry, energy sector, surgical instruments, high wear components, and general metallurgy, among others.

Modeling, simulation, and experimental study of personalized porous tooth structure formed by laser selective melting (SLM)

The work aims to study and summarize the technology methods for personalized design and 3D printing for the human tooth, mainly including scanning the human model of the oral cavity with the lost tooth, dealing with the point clouds data, reconstructing the dental crown and dental root with porous structure, simulating the deformation and stress of different porous structure, and printing the different unit body by SLM 3D printing with metal powder material titanium alloys TC4. Finally, experiments are conducted to verify the performances of the printed unit entity with a porous structure. The conclusion is that the porous structure designed is effective for a closer elastic modulus E=2.20-3.00 GPa to the Human cementum. It can increase the matching between the elastic modulus of the patient’s jaw bone, reduce the stress shielding effect, achieve increased bone bonding area, improve bone bonding efficiency, and improve the long stability of implant bone bonding. It also has a 20.44 % weight loss. It becomes lighter and more economical. Through the research, the rapid and personalized customization forms can be realized to promote the further development of the dental reconstruction area.

High-fidelity Modeling of Multilayer Building Process in Electron Beam Powder Bed Fusion: Build-quality Prediction and Formation-Mechanism Investigation

High-fidelity simulations of powder bed fusion (PBF) additive manufacturing have made significant progress over the past decade. In this study, an efficient two-dimensional frame was developed for simulating the electron beam PBF process with hundreds of tracks for the direct prediction of the build quality. The applicable parameter range of the developed model was determined by comparing the heat transfer with that in three-dimensional cases. Subsequently, powder deposition and selective melting were coupled for a continuous simulation of the multilayer process. Three powder deposition models were utilized to generate random powder particles, and their effects on the packing structure and the resultant simulated build quality were investigated. The predicted build quality was validated using experimental results from independent studies. By reproducing the building process, the defect development mechanism in a multilayer process was revealed for the coalescence behaviors of randomly distributed powder particles, which also confirmed the importance of simulation at the high-fidelity powder scale. The effects of key process parameters during multilayer and multi-track processes on the build quality were systematically investigated. In particular, the formation statuses of all tracks during the simulated building process were recorded and analyzed statistically, which provided crucial information on the printing process for understanding the building mechanism or performing uncertainty analysis.