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<p>Additively manufactured Ti6Al4V via laser powder bed fusion is one of the most researched and understood processes in the additive space. However, there are small lessons learned by users that come with experience as not many of the small details are published. This short paper mentions two small considerations that can turn problematic for users if not readily comprehended. These are the as-cut surfaces of wire electrical discharge machining and a cracking anomaly that can arise in build plate resurfacing. Focus on microstructural evaluations on these two features revealed minimal impact of the wire EDM process on part surfaces and provided notable examples of fine orthogonal cracks that can exist in the recast layer. The build plate anomaly included an altered microstructure that was confirmed as part of the rapid cooling of the first layers. Higher hardness phases and residual stresses were deemed to be the main contributors to the observed cracking. Findings and recommended approaches to mitigate cracking are discussed.</p>

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A Look at Two Nuisance Process Hurdles Encountered by New Laser Powder Bed Fusion Operators Printing Ti6Al4V

  • 期刊论文

  • 发表日期：

    2025年2月24日

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  • Rodolfo Villa,
  • Chris Billings,
  • Zahed Siddique,
  • Yingtao Liu

摘要

Additively manufactured Ti6Al4V via laser powder bed fusion is one of the most researched and understood processes in the additive space. However, there are small lessons learned by users that come with experience as not many of the small details are published. This short paper mentions two small considerations that can turn problematic for users if not readily comprehended. These are the as-cut surfaces of wire electrical discharge machining and a cracking anomaly that can arise in build plate resurfacing. Focus on microstructural evaluations on these two features revealed minimal impact of the wire EDM process on part surfaces and provided notable examples of fine orthogonal cracks that can exist in the recast layer. The build plate anomaly included an altered microstructure that was confirmed as part of the rapid cooling of the first layers. Higher hardness phases and residual stresses were deemed to be the main contributors to the observed cracking. Findings and recommended approaches to mitigate cracking are discussed.