The Effects Of Process Parameters On The Cyclical Life Of Ti-6al-4v Manufactured Via Laser Powder Bed Fusion

Additive manufacturing via Laser Powder Bed Fusion (LPBF) has already proven revolutionary technology. Due to its favorable strength-to-weight ratio, ti-6Al-4V, a popular titanium alloy, has already been implemented in the aerospace industry for various components. However, the quality validation in additively manufactured parts has always been an issue of concern, specifically under cyclic loading. Ti-6Al-4V samples were printed using LPBF with various process parameters to investigate these conditions further. The build was stress-relieved; however, the samples underwent no other post-processes maintaining their as-built surface. The process parameters were separated into five categories, including various laser powers and printing speeds, allowing for defects such as keyholing and Lack of Fusion (LoF).Furthermore, the other three chosen parameters were printed within the process window at separate locations. Cyclical flexural loading experiments were conducted using a 4-point bending fixture and a servo-hydraulic testing machine by MTS to investigate the fatigue life at various stress levels within the elastic region. Preliminary data from the experimentation of these unmachined rectangular specimens are presented and categorized by their printing parameters to compare their fatigue life under flexural conditions