Digital technology such as metal additive manufacturing (AM) provides flexible process design freedom to fabricate intricate three-dimensional structures layer-by-layer. However, its manufacturability relies on the fundamental understanding of melt pool physics and fluid (metal) dynamics. The effect of metal vapour and porosity induced during the laser-materials interaction can influence the additive manufacturability. In this work, composition-process relationship of laser-based powder-bed fusion (L-PBF) AM is studied via computational fluid dynamics modelling to rationalise solid-liquid-vapour transformation where empirical-based approach is used to generate thermo-physical property of about 100 nickel-based superalloys at the liquid state. It is found that with larger vapor mass loss, the porosity tends to be higher. However, the higher vapour mass loss means faster cooling rate. This is indicated that the thermal-fluid flow process, which is also governed by the thermo-physical property, strongly affects the additive manufacturability. Additive manufacturability map based upon porosity, cooling rate from liquid to solid, volatile mass loss criteria has been established to link the composition in nickel-based superalloys with their thermo-physical property. This offers a thermal-fluid science based tool in designing compositions of novel superalloys for AM applications.

金属增材制造 (AM) 等数字技术提供了灵活的工艺设计自由度，可以逐层制造复杂的 3D 结构。然而，其可制造性依赖于对熔池物理和流体（金属）动力学的基本理解。在激光与材料相互作用期间引起的金属蒸汽和孔隙率的影响会影响增材制造。在这项工作中，激光基粉末床融合（L-PBF) AM 通过计算流体动力学模型进行研究，以合理化固-液-气转换，其中使用基于经验的方法来生成大约 100 种镍基高温合金的液态热物理特性。发现蒸汽质量损失越大，孔隙率往往越高。然而，更高的蒸汽质量损失意味着更快的冷却速度。这表明热流体流动过程也受热物理性质控制，强烈影响添加剂的可制造性。已建立基于孔隙率、从液体到固体的冷却速率、挥发性质量损失标准的增材制造图，以将镍基高温合金中的成分与其热物理性能联系起来。