This article delves into optimizing and modeling input parameters for the Selective Laser Melting (SLM) process on Inconel 625. The primary aim is to investigate the microstructure within interlayer regions post-process optimization. For this study, 100 layers with a thickness of 40 µm each were produced. Utilizing the Design of Experiments (DOE) methodology, employing the Response Surface Method (RSM), the SLM process was optimized. Input parameters such as laser power, hatch distance, and laser speed were considered, while changes in hardness and roughness were taken as responses. Sample microstructure and surface alterations were assessed via SEM analysis. Surface and volumetric defects of Inconel 625 cubic samples were assessed. The porosity and lack of fusion, which were due to rapid post-powder melting solidification, prompted a detailed analysis of those flaws in both surface and internal aspects of the samples. The understanding of the formation of these imperfections can help in refining the process for enhanced integrity and performance of Inconel 625 printed material.
