Research on Density Prediction of Laser Powder Bed Fusion Process Parameters for IN718 Nickel-Based Superalloy Based on Machine Learning.

This study addresses the challenge of modeling the complex non-linear relationship between process parameters and relative density in selective laser melting (SLM) of IN718 nickel-based superalloy under small-sample conditions. A data-driven prediction framework integrating data augmentation, physics-informed feature engineering, machine learning, and model interpretability analysis was developed and systematically validated. Fourteen sets of experimental data covering both vertical and horizontal building directions were collected by varying laser power (P), scan speed (v), and hatch spacing (h). To overcome the small-sample limitation, three augmentation strategies-radial basis function (RBF) interpolation, generative adversarial network (GAN), and K-nearest neighbors (KNN)-were systematically compared under unified physical constraints combining local perturbation and volumetric energy density (E_vol) filtering, with Pearson correlation coefficient consistency used to select the optimal strategy. Eight physically meaningful input features were constructed, including E_vol and line energy density (E_line), explicitly embedding SLM process physics into the learning framework. Support vector regression (SVR), random forest (RF), and artificial neural network (ANN) models were trained and their hyperparameters were systematically optimized via exhaustive grid search combined with leave-one-out cross-validation (LOO-CV), ensuring robust model selection under small-sample constraints. A physics-based baseline model (E_vol quadratic fitting, LOO-CV average R