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Comprehensive reliability-quality integration framework for enhancing gear performance in laser powder bed fusion
Vikram Kumar Gupta1, Sanjay Kumar Chaturvedi2, Rajiv Nandan Rai2
1Subir Chowdhury School of Quality and Reliability, Indian Institute of Technology Kharagpur, Kharagpur, West Bengal, India. vikramgupta89@gmail.com.
Scientific Reports
|May 28, 2026
Summary
This study presents a Reliability-Quality-Reliability (RQR) framework for Laser Powder Bed Fusion (L-PBF) gears. It links manufacturing dependability, process quality, and product reliability to enhance gear performance and efficiency.
Area of Science:
- Materials Science and Engineering
- Manufacturing Technology
- Reliability Engineering
Background:
- Laser Powder Bed Fusion (L-PBF) is a key additive manufacturing technique for complex components like gears.
- Ensuring reliability and quality in L-PBF manufactured gears is critical for their performance and operational efficiency.
- Existing frameworks often lack a holistic approach integrating manufacturing dependability, process quality, and product reliability.
Purpose of the Study:
- To introduce a comprehensive framework integrating reliability assurance and quality control in L-PBF gear manufacturing.
- To establish the Reliability-Quality-Reliability (RQR) chain model to highlight the reciprocal links between system dependability, process quality, and product reliability.
- To provide a systematic approach for iterative process optimization and system-wide improvements in L-PBF gear production.
Main Methods:
- Development of the Reliability-Quality-Reliability (RQR) chain model.
- Analysis of internal flaws (e.g., lack of fusion, porosity) and external issues (e.g., wear, geometric deviation) affecting L-PBF gears.
- Evaluation of process parameters (laser power, scan speed, layer thickness) and post-processing treatments (HIP).
- Demonstration of the framework using independent peer-reviewed datasets for methodological and benchmark validation.
Main Results:
- Internal and external flaws significantly compromise the structural integrity and reliability of L-PBF gears.
- Experimental reliability decreased significantly during extended operation when both internal and external faults were considered.
- Process parameters critically influence microstructural integrity, fatigue life, and wear reliability.
- Post-processing treatments like Hot Isostatic Pressing (HIP) markedly enhance gear performance.
Conclusions:
- The RQR-based performance matrix offers a systematic framework for defect reduction and enhanced fatigue and wear reliability in L-PBF gears.
- The framework facilitates sustainable, high-quality manufacturing of L-PBF-manufactured gears.
- Further independent experimental verification of the proposed RQR framework is recommended.
