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 (PBF-LB) 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 maps 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.