Investigation of an Increased Particle Size Distribution of Ti-6Al-4V Powders Used for Laser-Based Powder Bed Fusion of Metals

This study investigates the potential benefits of integrating coarser particle size distributions (PSDs) of 45–106 µm into laser-based powder bed fusion of metals (PBF-LB/M), aiming to reduce costs while maintaining quality standards. Despite the considerable advantages of PBF-LB/M for producing intricate geometries with high precision, the high cost of metal powders remains a barrier to its widespread adoption. By exploring the use of coarser PSDs, particularly from electron beam-based powder bed fusion of metals (PBF-EB/M), significant cost-saving opportunities are identified. Through a comprehensive powder characterization, process analysis, and mechanical property evaluation, this study demonstrates that PBF-LB/M can effectively utilize coarser powders while achieving comparable mechanical properties as those produced with a 20–53 µm PSD. Adaptations to the process parameters enable the successful processing of coarser powders, maintaining high relative density components with minimal porosity. Additionally, market surveys reveal substantial cost differentials between PBF-LB/M and PBF-EB/M powders, indicating a 40% cost reduction potential for the feedstock material by integrating coarser PSDs into PBF-LB/M. Overall, this study provides valuable insights into the economic and technical feasibility of printing with coarser powders in PBF-LB/M, offering promising avenues for cost reduction without compromising quality, thus enhancing competitiveness and the adoption of the technology in manufacturing applications.