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Numerical and experimental study of Ti6Al4V components manufactured using powder bed fusion additive manufacturing

: Zielinski, J.; Mindt, H.-W.; Düchting, J.; Schleifenbaum, J.H.; Megahed, M.

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JOM. The journal of the Minerals, Metals & Materials Society 69 (2017), No.12, pp.2711-2718
ISSN: 0148-6608
ISSN: 1047-4838
ISSN: 1543-1851
Journal Article, Electronic Publication
Fraunhofer ILT ()

Powder bed fusion additive manufacturing of titanium alloys is an interesting manufacturing route for many applications requiring high material strength combined with geometric complexity. Managing powder bed fusion challenges, including porosity, surface finish, distortions and residual stresses of as-built material, is the key to bringing the advantages of this process to production main stream. This paper discusses the application of experimental and numerical analysis towards optimizing the manufacturing process of a demonstration component. Powder characterization including assessment of the reusability, assessment of material consolidation and process window optimization is pursued prior to applying the identified optima to study the distortion and residual stresses of the demonstrator. Comparisons of numerical predictions with measurements show good correlations along the complete numerical chain.