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Updated: Jun 11, 2025
Production of Single Tracks of Ti-6Al-4V by Directed Energy Deposition to Determine the Layer Thickness for Multilayer Deposition
Published on: March 13, 2018
Effects of Process Parameters and Process Defects on the Flexural Fatigue Life of Ti-6Al-4V Fabricated by Laser
Brandon Ramirez1,2, Cristian Banuelos1,2, Alex De La Cruz1,2
1Department of Aerospace and Mechanical Engineering, University of Texas at El Paso, El Paso, TX 79968, USA.
Abstract:
The fatigue performance of laser powder bed fusion-fabricated Ti-6Al-4V alloy was investigated using four-point bending testing. Specifically, the effects of keyhole and lack-of-fusion porosities along with various surface roughness parameters, were evaluated in the context of pore circularity and size using 2D optical metallography. Surface roughness of Sa = 15 to 7 microns was examined by SEM, and the corresponding fatigue performance was found to vary by 102 cycles to failure. The S-N curves for the various defects were also correlated with process window examination in laser beam power-velocity (P-V) space. Basquin's stress-life relation was well fitted to the experimental S-N curves for various process parameters except keyhole porosity, indicating reduced importance for LPBF-fabricated Ti-6Al-4V alloy components.
