Investigating Melt Pool Dimensions in Laser Powder Bed Fusion of Nitinol: An Analytical Approach

Nitinol (NiTi) has gained popularity across various industries due to its shape memory and superelastic properties. Recently, additive manufacturing (AM) has been increasingly utilized to produce NiTi components. This study focuses on single‐track nitinol samples fabricated via powder bed fusion using laser beam (PBF‐LB). Investigating the effects of laser power and scanning speed on melt pool dimensions reveals that melt pool width increases linearly with laser power and decreases logarithmically with scanning speed. However, melt pool depth exhibits outliers that deviate from these trends. Three analytical models are evaluated to predict melt pool dimensions, generally aligning with experimental trends. Notably, the Eagar–Tsai model delivers the most accurate predictions for melt pool width, with a mean absolute error of less than 10%, while the Gladush–Smurov model is more reliable for melt pool depth predictions, showing a mean absolute error under 20%. In contrast, the Rosenthal equation yields less reliable results for both dimensions. This suggests that a combined approach utilizing the strengths of both the Eagar–Tsai and Gladush–Smurov models may provide the most accurate predictions for the melt pool profile of NiTi in PBF‐LB.