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Related Experiment Video

Updated: May 15, 2025

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Improving Laser Powder Bed Fusion IN718 Process Development Efficiency by Eliminating Pore Defects of Specified Size.

Yuzhong Wang1,2,3, Wenhua Guo1,2,3, Wenxian Li1,2,3

  • 1School of Mechanical Engineering, Xi'an Jiaotong University, Xi'an 710049, China.

Materials (Basel, Switzerland)
|May 14, 2025
PubMed
Summary

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This study introduces a new method to quickly find optimal parameters for laser powder bed fusion (L-PBF) of IN718, eliminating defects and improving mechanical properties. The approach ensures high density and superior performance compared to traditional methods.

Area of Science:

  • Additive Manufacturing
  • Materials Science
  • Mechanical Engineering

Background:

  • Laser powder bed fusion (L-PBF) is crucial for advanced manufacturing.
  • Identifying optimal process windows is key to reducing costs and ensuring part quality.
  • Defect control, particularly porosity, is a major challenge in L-PBF IN718.

Purpose of the Study:

  • To accelerate the development of process windows for L-PBF IN718.
  • To eliminate specific-size pore defects (≥ 90 μm).
  • To introduce and validate a novel density-porosity similarity evaluation method (DPSEM).

Main Methods:

  • Developed and applied a novel density-porosity similarity evaluation method (DPSEM) for porosity data validation from computed tomography (CT).
  • Utilized the response surface method to locate the fully dense forming window (relative density ≥ 99%).
Keywords:
Inconel 718laser powder bed fusion (L-PBF)mechanical propertiespore defects eliminationresponse surface methodology

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  • Conducted comparative analysis against a traditional relative density (RD) model.
  • Main Results:

    • The DPSEM method accurately located the fully dense window (≥ 99% relative density) within 18-1000 J/mm³ in a single test.
    • Achieved a maximum density of 99.5% and eliminated defects ≥ 90 μm.
    • The DPSEM method resulted in superior mechanical properties (UTS: 1155 MPa, YS: 908 MPa) compared to the RD model (UTS: >910 MPa), which showed compromised performance due to defects and precipitation.

    Conclusions:

    • The proposed DPSEM is an effective method for accelerating process window development in L-PBF.
    • DPSEM enables precise control over defect elimination, leading to enhanced material density and mechanical performance.
    • This approach offers significant advantages over traditional RD models for L-PBF IN718 optimization.