A New Approach to Empirical Optimization of Laser Powder Bed Fusion Process for Ti6Al4V Parts

Abstract Optimization of all the process parameters for laser powder bed fusion (L-PBF), considering effects individual on Ti6Al4V fabricated parts, can be complex and challenging. Therefore, first time, three main variable (laser power, scan speed, hatch spacing) outcomes (surface roughness, bulk porosity, production rate parts) were studied in this work. Then, combination above-mentioned form volumetric energy density (VED) was investigated order to establish a practical method optimization making parts with desired quality targets, i.e., smoothest surface, lowest porosity higher rate. It revealed that although VED is reliable metric parameters, some thresholds ranges should considered spacing. demonstrated by employing an optimum power 180 W or 270 changing speed spacing keep range 50-100 J/mm 3 , fabrication samples micro-roughness R < 10 µm less than 0.15% achievable. In addition, surface L-PBF may appear two categories morphology; wavy classified “meso-roughness topography” non-wavy termed “micro-roughness”. Since there not any correlation between value roughness meso-rough their besides, far from optimized included final results. However, it realized micro-rough surfaces, could accurately indicate content samples.