Over the last decade, laser powder bed fusion (LPBF) received increased attention as a method of producing complex-shaped products from various materials. Recent results indicate the potential of this technology for the production of intermetallic NiTi alloys with shape memory. Several studies have demonstrated a strong influence of the LPBF process conditions on the resulting material properties, i.e., the martensitic phase transformation temperatures, reversible/irreversible strain after cyclic loading, phase composition, chemical composition, etc. However, the mechanisms of functional properties altering during LPBF consolidation remain unexplored in the present state-of-the-art. This study aims to advance the knowledge about tailoring material properties of NiTi under laser influence. In this work, thin-walled samples were manufactured from pre-alloyed NiTi powder via LPBF in a wide window of laser power and scanning speed, excluding hatch spacing by employing a single track-based scanning strategy to reveal the pure effect of the laser’s influence. NiTi samples were characterized by various methods such as differential scanning calorimetry, X-ray diffraction, and mechanical tests. Established relationships between NiTi properties and the LPBF process conditions provide the basis for the development of NiTi production protocols with controlled functional properties.

Laser powder bed fusion (LPBF) is an advanced additive manufacturing method, but its productivity is relatively low, which limits its application. Performance can be increased without hardware modifications by enlarging the powder-layer thickness. However, this approach requires deeper investigation because the probability of defects (keyhole porosity, lack of fusion) rises substantially, and experiments become costly since each thickness value requires a separate LPBF run. High-fidelity simulation under such conditions can reduce the experimental workload. Reliable predictions, however, require numerous thermophysical parameters; reported values are often inconsistent or unavailable, and few studies have quantified their influence on simulation outcomes. A Lattice Boltzmann-based model is adopted to simulate the keyhole melting mode of AlSi10Mg. The effects of laser spot diameter, laser absorptivity, and the temperature dependence of thermal diffusivity and surface tension on the results are investigated. Predicted melt-pool morphologies are compared with cross-sections of experimental single tracks.