Influence of process parameters on layer build-up and microstructure of Ti6Al4V (ELI) alloy on the optomec LENS

Abstract

The Optomec Laser Engineered Net Shaping (LENS®) system is a laser-based platform that relies on computer-aided design (CAD) files to design and produce 3D printed components. This system is comprised of a 1 kW laser used to melt metal powders into a desired shape onto a substrate. The manufactured part is built up layer by layer until the final 3D printed shape is achieved. In this study, cylindrical shapes of 15 mm diameter and 11 mm height were built-up by varying process parameters such as laser power, scanning speed and powder flow rate in order to determine their influence on the physical properties, as well as microstructure of Ti6Al4V ELI (Extra-Low Interstitials) build-ups conducted on the LENS® system for the qualification of additive manufacturing of biomedical components. Results showed that at higher laser intensities used, the desired shapes were not achieved, but produced higher build heights. From the results obtained, sample medical components were built up using parameters that produced the desired cylindrical shapes.