Understanding Process Variation of Aerospace Alloys Processed by Laser Powder Bed Fusion

Powder bed metal additive manufacturing processes offer unique capabilities for novel aerospace materials and complex designs in the production of aerospace components. Understanding the effect of build parameters on microstructure and properties of AM-produced materials is necessary to control the manufacturing process and reduce variation in the final part. Laser power, laser speed, scanning strategy, and layer thickness are some of the build parameters that control microstructure and mechanical properties on the final part produced in laser powder bed fusion systems. In this study, a methodology for understanding variation and developing process parameters using ATI’s SLM 125 laser system will be discussed. These experiments lead to improved microstructure and mechanical properties of Ni, Ti, and Al aerospace powder alloys processed in a laser powder bed fusion system.