Reliability of Thermal Conduction-Based Melt Pool Simulations Using In-Process Thermal Camera and Post-Process Single-Track Measurements

Laser Powder Bed Fusion (LPBF) is a complex manufacturing process that depends on precise control of printing parameters and melt pool geometry, which directly influence defect formation and final part quality. This study evaluated the reliability of a simplified thermal conduction-based melt pool model by combining post-process metallographic analysis with in situ dual-wavelength infrared thermal imaging. Experimental data were obtained through single-track printing on 316L, IN625, and CoCr alloys across a wide range of parameters. The simulated melt pool length showed strong agreement with thermal camera measurements (R²_adj > 0.78), while the width showed moderate but consistent correlation (R²_adj > 0.52). For melt pool depth, the model systematically deviated due to its inability to capture keyhole melting, although a strong linear correlation was still observed (R²_adj > 0.86). Cross-validation between metallographic measurements and thermal imaging revealed only a 6–9% discrepancy, confirming the reliability of both methods and the potential of dual-wavelength cameras for industrial process monitoring. Overall, the model proves to be a reliable tool for predicting melt pool surface geometry specifically within the conduction melting regime, while its predictive capability degrades significantly in the keyhole regime, where simulated peak temperatures reach up to 7000 °C and melt pool depth errors escalate due to the disregard of recoil pressure, liquid and vapor dynamics.