The production of dense samples produced by laser powder bed fusion (LPBF) is mainly determined by the choice of the best combination of construction parameters. Parameter optimization is the first step in the definition of an LPBF process for new alloys or systems. With this goal, much research uses the single scan track (SST) approach for a preliminary parameter screening. This study investigates the definition of a computer-aided method by using an automatic on top analysis for the characterization of SSTs, with the aim of finding ranges of laser power and scan speed values for massive production. An innovative algorithm was implemented to discard non-continuous scans and to measure the SSTs quality using three regularity indexes. Only open source software were used to fine tune this approach. The obtained results on Al4Cu and AlSi10Mg realized with two different commercial systems suggest that it is possible to use this method to easily narrow the process parameter window that allows the production of dense samples.

Thanks to its high weldability, Inconel 625 (IN625) can be easily processed by laser powder bed fusion (LPBF). After production, this alloy is typically subjected to specific heat treatments to design specific microstructure features and mechanical performance suitable for various industrial applications, including aeronautical, aerospace, petrochemical, and nuclear fields. When employed in structural applications, IN625 can be used up to around 650 °C. This limitation is mainly caused by the transformation of metastable γ″ phases into stable δ phases occurring under prolonged thermal exposure, which results in drastically reduced ductility and toughness of the alloy. Because the microstructure and mechanical properties change during thermal exposure, it is essential to study the material simulating possible service temperatures. In the current study, LPBFed IN625 samples were solution-annealed and then subjected to thermal exposure at 650 °C for different times up to 2000 h. The characterization focused on the evolution of the main phases, γ″ and δ phases, and their influence on the hardness evolution. The microstructure and hardness of the heat-treated LPBFed IN625 samples were compared with data related to the traditionally processed IN625 alloy (e.g., wrought state) reported in the literature.