A Lattice Boltzmann Thermal Model for Predicting Melt Pool Geometry in Selective Laser Melting of AlSi10Mg and 316L Stainless Steel

Selective laser melting (SLM) is a complex additive manufacturing process involving rapid laser–material interaction, steep thermal gradients, and phase change phenomena. In this work, a two-dimensional thermal model based on the lattice Boltzmann method (LBM) is developed to simulate the SLM process of AlSi10Mg and 316L stainless steel (316L SS) alloys. The model captures the laser–material interaction, layer-by-layer deposition, phase change behavior, and heat transfer mechanisms, including conduction and convection. Experimental observations of melt pool width and depth were also performed on the microstructures of the two SLM alloys in order to compare the results with the numerical predictions. For the AlSi10Mg alloy, good agreement is obtained, with relative errors of 19.13% in melt pool width and 7.58% in depth, accurately capturing melt pool penetration and remelting behavior. In contrast, moderate deviations are observed for 316L SS, indicating a higher sensitivity to thermophysical properties and suggesting that further model refinement is required. Overall, the results demonstrate the capability of the LBM framework as an efficient and robust tool for analyzing thermal behavior in SLM and for supporting process parameter optimization.