Laser Powder Bed Fusion Parameters Optimization for Enhanced Mechanical Properties of EOS Co-Cr Dental Alloy

This research explores how variations in laser powder bed fusion (LPBF) parameters-laser power (P), scanning speed (v), and base plate preheating temperature (ϑ_p)-affect the mechanical properties of the EOS Co-Cr SP2 dental alloy. A central composite design (CCD) was used to optimize the process parameters. Mechanical testing focused on crucial properties for dental applications, including yield strength (Rp_0.2), elongation (ε), toughness (KV_a), and flexural strength (R_ms). Microstructural analysis was conducted using light and electron microscopy, while XRD identified microstructural phases. Statistical analysis (ANOVA, Scheffé post hoc test, α = 0.05) revealed significant effects of P, v, and ϑ_p on the mechanical properties. Response surface models (RSMs) were developed, and optimal parameters were determined to achieve maximum toughness and flexural strength. Maximum values were obtained with laser power above 205 W and base plate preheating at 310 °C. The mathematical model predicted toughness values with less than 5% deviation from experimental results, indicating high accuracy.