Fatigue-based process window for laser beam powder bed fusion additive manufacturing

Processing defects remain the primary cause for fatigue failure of laser beam powder bed fusion (PBFLB) produced components. Accordingly, process mapping methodologies have been extensively developed to identify optimal processing parameters to avoid defects. For structure -critical applications, it is necessary to validate the defect -based process map through fatigue testing. We quantify the defect structure (porosity) process map for PBF-LB Ti-6Al-4V based on defect populations and fatigue properties. The defect populations were measured in samples fabricated at constant power and small increments in scanning velocity using X-ray micro -computed tomography and 2D metallography and analyzed using a number density approach. Furthermore, 4 -point bend fatigue testing was used to establish stress -cycles to failure properties. Our results reveal distinct defect populations in both keyhole and lack -of -fusion defect regimes, with continuous variation in defect density. The number density -based defect size quantity strongly correlates with process parameters, peak stress, and initiating defect size, offering a quantitative approach to establish process -defect -fatigue relationships. We conclude that the process window exists just as clearly for fatigue as it does for defects, although more sensitive to variability in defects. Consequently, within this fatigue -based process window , one can expect to consistently produce dense components with superior fatigue properties.