Selective laser melting (SLM) is one of the most promising processes in the Additive Manufacturing of metals because of the possibility to fabricate complex geometry parts with a wide range of materials. The molten pool dimensions are notoriously crucial for the production of high quality parts, in terms of mechanical properties and roughness, and to control the 'balling' phenomenon. In the past, several studies have been conducted to monitor temperature gradient and thermal history, stress and deformation field, balling occurrence, effect of volume shrinkage and the effect of process parameters on temperature evolution. Up to now, very few works are available in literature on the effects of the process parameters on the molten pool shape and dimensions: moreover, they also neglect the simultaneously effect of various physical factors. In this work, an integrated analytical model, consisting of three sub-models (thermal, optical and melting sub-models), with the purpose to forecast the molten pool dimensions in terms of width and depth, was developed. An experimental plan has been carried out, processing the 18 maraging 300 steel, to demonstrate the capability and the accuracy of the presented model. The obtained results demonstrate that the integrated analytical model led to optimal forecasting.
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