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Optimising Surface Roughness and Density in Titanium Fabrication via Laser Powder Bed Fusion.

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Summary

Optimizing Laser Powder Bed Fusion (LPBF) parameters for Ti6Al4V alloy enhances material density and surface finish. This study achieved 99.54% relative density and improved surface roughness, expanding LPBF applications.

Keywords:
ANOVATi6Al4Vdesign of experimentslaser powder bed fusionprocess parameters

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Area of Science:

  • Materials Science and Engineering
  • Additive Manufacturing
  • Metallurgy

Background:

  • Titanium alloy Ti6Al4V offers excellent lightweight, strength, and corrosion resistance, ideal for aerospace.
  • Laser Powder Bed Fusion (LPBF) enables complex part fabrication but faces challenges in surface quality and porosity.
  • Optimizing LPBF process parameters is crucial for realizing the full potential of Ti6Al4V components.

Purpose of the Study:

  • To investigate and optimize LPBF process parameters for Ti6Al4V alloy.
  • To improve the density and surface finish of LPBF-processed Ti6Al4V components.
  • To address challenges of surface quality and porosity in LPBF of Ti6Al4V.

Main Methods:

  • Utilized Design of Experiments (DoE) and Analysis of Variance (ANOVA) for statistical optimization.
  • Systematically varied laser power, laser scan speed, and hatch space parameters.
  • Evaluated relative density and surface roughness (top and side) of fabricated Ti6Al4V parts.

Main Results:

  • Identified optimal LPBF parameters: 175 W laser power, 1914 mm/s scan speed, and 53 µm hatch space.
  • Achieved a high relative density of 99.54% for Ti6Al4V components.
  • Reduced top surface roughness to 2.6 µm and side surface roughness to 4.3 µm.

Conclusions:

  • Demonstrated the effectiveness of DoE and ANOVA in optimizing LPBF for Ti6Al4V.
  • The optimized process significantly enhances Ti6Al4V component quality, overcoming limitations.
  • This research expands the applicability of LPBF for high-performance metal parts.