{"status":"ok","message-type":"work","message-version":"1.0.0","message":{"indexed":{"date-parts":[[2026,9,1]],"date-time":"2026-09-01T05:16:56Z","timestamp":1788239816015,"version":"build-2803163510"},"reference-count":42,"publisher":"MDPI AG","issue":"17","license":[{"start":{"date-parts":[[2026,8,30]],"date-time":"2026-08-30T00:00:00Z","timestamp":1788048000000},"content-version":"vor","delay-in-days":0,"URL":"https:\/\/creativecommons.org\/licenses\/by\/4.0\/"}],"funder":[{"name":"I-Form, the Science Foundation Ireland Research Centre for Advanced Manufacturing"},{"name":"Advanced Metallic Systems Centre of Doctoral Training"},{"DOI":"10.13039\/100019247","name":"ANSYS Inc.","doi-asserted-by":"crossref","id":[{"id":"10.13039\/100019247","id-type":"DOI","asserted-by":"crossref"}]},{"DOI":"10.13039\/501100001602","name":"Science Foundation Ireland","doi-asserted-by":"publisher","award":["18\/EPSRC-CDT\/3584"],"award-info":[{"award-number":["18\/EPSRC-CDT\/3584"]}],"id":[{"id":"10.13039\/501100001602","id-type":"DOI","asserted-by":"publisher"}]},{"DOI":"10.13039\/501100001602","name":"Science Foundation Ireland","doi-asserted-by":"publisher","award":["16\/RC\/3872"],"award-info":[{"award-number":["16\/RC\/3872"]}],"id":[{"id":"10.13039\/501100001602","id-type":"DOI","asserted-by":"publisher"}]},{"DOI":"10.13039\/501100001602","name":"Science Foundation Ireland","doi-asserted-by":"publisher","award":["21\/RC\/10295_P2"],"award-info":[{"award-number":["21\/RC\/10295_P2"]}],"id":[{"id":"10.13039\/501100001602","id-type":"DOI","asserted-by":"publisher"}]},{"DOI":"10.13039\/501100000266","name":"Engineering and Physical Sciences Research Council","doi-asserted-by":"publisher","award":["EP\/S022635\/1"],"award-info":[{"award-number":["EP\/S022635\/1"]}],"id":[{"id":"10.13039\/501100000266","id-type":"DOI","asserted-by":"publisher"}]},{"award":["EP\/S022635\/1"],"award-info":[{"award-number":["EP\/S022635\/1"]}],"id":[{"id":"https:\/\/ror.org\/0439y7842","id-type":"ROR","asserted-by":"publisher"}]}],"content-domain":{"domain":[],"crossmark-restriction":false},"short-container-title":["Materials"],"abstract":"<jats:p>Powder bed fusion\u2013laser beam (PBF-LB) of nickel\u2013titanium (NiTi) has attracted increasing interest in aerospace, biomedical, and energy applications owing to its shape memory and superelastic properties, combined with the capability to fabricate complex geometries. However, the strong sensitivity of NiTi to thermal history and process variability makes predictive modeling and process parameter selection challenging. In this work, a physics-guided decision-support framework is developed for melt pool prediction and stability assessment during the PBF-LB processing of NiTi. A high-fidelity thermal finite element model incorporating CALPHAD-derived, temperature-dependent material properties was calibrated using a subset of experimental measurements and independently validated against additional experimental melt pool data. The calibrated model demonstrated good agreement with experiments, yielding mean absolute percentage errors of 4.22% and 5.63% for melt pool width and depth, respectively, on the validation dataset. A multi-output random forest surrogate trained on the validated simulation dataset enabled rapid prediction of melt pool geometric features, achieving test-set R2 values exceeding 0.95, together with low MAE and RMSE values, while five-fold cross-validation confirmed robust predictive performance. The proposed framework integrates surrogate predictions with physics-based melt pool stability criteria to rapidly identify physically feasible processing conditions, thereby providing a computationally efficient foundation for future supervisory process control strategies.<\/jats:p>","DOI":"10.3390\/ma19173696","type":"journal-article","created":{"date-parts":[[2026,8,31]],"date-time":"2026-08-31T04:24:03Z","timestamp":1788150243000},"page":"3696","update-policy":"https:\/\/doi.org\/10.3390\/mdpi_crossmark_policy","source":"Crossref","is-referenced-by-count":0,"title":["Physics-Guided Decision-Support Framework for Melt Pool Prediction and Process Stability in Laser Powder Bed Fusion of Nitinol"],"prefix":"10.3390","volume":"19","author":[{"ORCID":"https:\/\/orcid.org\/0009-0008-2925-3331","authenticated-orcid":false,"given":"Sampreet","family":"Rangaswamy","sequence":"first","affiliation":[{"name":"I-Form, Advanced Manufacturing Research Centre, Dublin City University, Glasnevin, D09 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Avenue, Suite 663, Cottonwood Heights, UT 84047, USA"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"validation","vocabulary":"credit"},{"role":"resources","vocabulary":"credit"},{"role":"writing-review-editing","vocabulary":"credit"}]},{"ORCID":"https:\/\/orcid.org\/0009-0000-0476-652X","authenticated-orcid":false,"given":"Abdul Khader","family":"Khan","sequence":"additional","affiliation":[{"name":"Ansys Inc., 6975 Union Park Avenue, Suite 663, Cottonwood Heights, UT 84047, USA"}],"role":[{"vocabulary":"crossref","role":"author"},{"role":"methodology","vocabulary":"credit"},{"role":"formal-analysis","vocabulary":"credit"},{"role":"writing-review-editing","vocabulary":"credit"}]},{"given":"Chong","family":"Teng","sequence":"additional","affiliation":[{"name":"Ansys Inc., 6975 Union Park Avenue, Suite 663, Cottonwood Heights, UT 84047, 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Manuf."},{"key":"ref_2","doi-asserted-by":"crossref","first-page":"032001","DOI":"10.1088\/2631-7990\/acc7d9","article-title":"Laser powder bed fusion additive manufacturing of NiTi shape memory alloys: A review","volume":"5","author":"Wei","year":"2023","journal-title":"Int. J. Extrem. Manuf."},{"key":"ref_3","doi-asserted-by":"crossref","unstructured":"Cobbinah, P.V., Nzeukou, R.A., Onawale, O.T., and Matizamhuka, W.R. (2020). Laser Powder Bed Fusion of Potential Superalloys: A Review. Metals, 11.","DOI":"10.3390\/met11010058"},{"key":"ref_4","doi-asserted-by":"crossref","unstructured":"Dejene, N.D., and Lemu, H.G. (2023). Current Status and Challenges of Powder Bed Fusion-Based Metal Additive Manufacturing: Literature Review. 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Volume 2: Advanced Manufacturing.","DOI":"10.1115\/IMECE2024-145983"},{"key":"ref_10","first-page":"103122","article-title":"Time-efficient surrogate models of thermal modeling in laser powder bed fusion","volume":"59","author":"Li","year":"2022","journal-title":"Addit. Manuf."},{"key":"ref_11","doi-asserted-by":"crossref","first-page":"369","DOI":"10.1007\/s10845-022-02038-4","article-title":"Development of a surrogate model for high-fidelity laser powder-bed fusion using tensor train and gaussian process regression","volume":"34","author":"Kizhakkinan","year":"2023","journal-title":"J. Intell. Manuf."},{"key":"ref_12","first-page":"011003","article-title":"Data-Efficient Surrogate Model for Rapid Prediction of Temperature Evolution in a Microscale Selective Laser Sintering System","volume":"11","author":"Grose","year":"2023","journal-title":"J. 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Technol."},{"key":"ref_41","first-page":"178","article-title":"Modeling of heat transfer, fluid flow and solidification microstructure of nickel-base superalloy fabricated by laser powder bed fusion","volume":"12","author":"Lee","year":"2016","journal-title":"Addit. Manuf."},{"key":"ref_42","doi-asserted-by":"crossref","first-page":"22","DOI":"10.1016\/j.ijmachtools.2017.03.004","article-title":"Laser powder bed fusion of nickel alloy 625: Experimental investigations of effects of process parameters on melt pool size and shape with spatter analysis","volume":"121","author":"Criales","year":"2017","journal-title":"Int. J. Mach. Tools Manuf."}],"container-title":["Materials"],"original-title":[],"language":"en","link":[{"URL":"https:\/\/www.mdpi.com\/1996-1944\/19\/17\/3696\/pdf","content-type":"unspecified","content-version":"vor","intended-application":"similarity-checking"}],"deposited":{"date-parts":[[2026,9,1]],"date-time":"2026-09-01T04:26:54Z","timestamp":1788236814000},"score":1,"resource":{"primary":{"URL":"https:\/\/www.mdpi.com\/1996-1944\/19\/17\/3696"}},"subtitle":[],"short-title":[],"issued":{"date-parts":[[2026,8,30]]},"references-count":42,"journal-issue":{"issue":"17","published-online":{"date-parts":[[2026,9]]}},"alternative-id":["ma19173696"],"URL":"https:\/\/doi.org\/10.3390\/ma19173696","relation":{},"ISSN":["1996-1944"],"issn-type":[{"value":"1996-1944","type":"electronic"}],"subject":[],"published":{"date-parts":[[2026,8,30]]}}}