Fig. 1. Size distribution of powder bed particles

Fig. 2. Powder bed parameters and modeling process. (a) Before the blade movement; (b) blade moves forward along X-axis to pave powder; (c) final powder bed model

Fig. 3. Morphology of AlSi10Mg powder particles

Fig. 4. Temperature-dependent thermophysical properties of AlSi10Mg^[30]. (a) Thermal conductivity and density; (b) specific heat and viscosity

Fig. 5. Scan strategy

Fig. 6. Comparison between simulated and measured track morphology. (a) Overall morphology of the track; (b) cross-section morphology of the track

Fig. 7. Three-dimensional and XOZ section morphology of molten pool. (a) Three-dimensional morphology; (b) XOZ section morphology

Fig. 8. Variation of YOZ section morphology of molten pool with time. (a) 32 μs; (b) 62 μs; (c) 82 μs; (d) 118 μs; (e) 185 μs; (f) 246 μs

Fig. 9. Track morphology under different laser powers. (a) 150 W; (b) 250 W; (c) 325 W; (d) 425 W; (e) 500 W

Fig. 10. Flow field of molten pool with balling. (a) 230 μs; (b) 270 μs; (c) 300 μs

Fig. 11. Variation of porosity of single track with laser power. (a) 150 W; (b) 250 W; (c) 325 W

Fig. 12. Flow field of molten pool with spatter

Fig. 13. Multi-track morphology under different hatch spaces at laser power of 350 W

Fig. 14. Multi-track morphology under different hatch spaces at laser power of 475 W. (a) 110 μm; (b) 140 μm

Fig. 15. Multi-layer AM simulation process. (a) Intercepting part of the first layer of tracks; (b) paving multi-layer AM powder bed;(c) the second layer of AM simulation

Fig. 16. Formation of interlayer porosity at section 1. (a) 0 μs; (b) 200 μs; (c) 573 μs; (d) 1100 μs

Fig. 17. Formation of interlayer porosity at section 2. (a) 0 μs; (b) 197 μs; (c) 506 μs; (d) 976 μs; (e) 1100 μs

Fig. 18. Variation of porosity with laser power

Fig. 19. Comparison between simulated and measured single track morphology. (a) 150 W; (b) 250 W; (c) 325 W; (d) 425 W

Fig. 20. Comparison between simulated and measured morphology of Z-section of formed parts