This work reports on employing X-ray computed tomography (XCT) and optical microscopy to investigate the causal relationships between printing parameters, pore properties, and porosity in 316L stainless steel samples additively manufactured by Laser Powder Bed Fusion (LPBF). The porosity is very similar for both investigation methods. XCT provides more accurate results for large lack of fusion pores, while optical results are more accurate for small keyhole pores. These results were employed to develop mathematical models to determine how printing parameters influence pore properties and overall porosity. The developed optical and XCT mathematical models reveal that power is the most significant factor affecting pore properties and overall porosity. Pore number and mean diameter decrease and sphericity increases with increasing power. Overall porosity is negatively correlated with power, indicating that the higher the power, the lower the overall porosity. Attention should also be paid to the quadratic effects of power, velocity and hatch spacing on porosity, revealing an inverse change in porosity after a certain threshold. Power interacts with velocity and hatch spacing, suggesting that changes in power affect the influence of velocity and hatch spacing on porosity, and vice versa. The interaction of velocity and hatch spacing is not significant. Both models successfully predicted optimal printing parameter sets as validated by experimental measurements.

Laser powder bed fusion (L-PBF) is a metal additive manufacturing (AM) technique that produces a unique microstructure significantly different from wrought microstructure. Inconel 625 (IN625) is an alloy widely used to manufacture complex parts, but it comes with its own unique challenges. The alloy is prone to precipitation under elevated temperatures, which makes designing suitable heat treatment to tailor the desired microstructure and mechanical properties critical. Traditional heat treatment for wrought IN625 cannot be applied to L-PBF IN625; therefore, it is vital to understand the evolution of precipitates on the way to complete recrystallization. This study focuses on these precipitates in IN625 produced by the L-PBF technique. Heat treatments at 700 °C, 900 °C, and 1050 °C were performed separately to encourage the precipitation of strengthening γ″, the detrimental δ phase, and the dissolution of precipitates, respectively. γ″ precipitates were found in the as-printed condition and at 700 °C. δ precipitates were detected at 700 and 900 °C. Carbides and Al-rich oxides were observed in all conditions of L-PBF IN625. Texture analysis showed grain growth along the build direction with strong (100) texture at temperatures up to 900 °C. Weak and random texture with equiaxed grains was observed at 1050 °C, which is similar to wrought IN625.