Effect of Powder Degradation on the Fatigue Behavior of Additively Manufactured As-Built Ti-6Al-4V

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Carrion, Patricio E.
Soltani-Tehrani, Arash
Thompson, Scott M.
Shamsaei, Nima

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University of Texas at Austin


Additive manufacturing (AM) technology has enabled many industries to generate functional parts with an increased level of complexity via a layer-by-layer melting. In laser-powder bed fusion (L-PBF), the most commonly used AM process for metals, powder is often recycled due to its high cost. However, there is no comprehensive study on how recycling powder affects its rheological properties, and the mechanical and fatigue behavior of the final manufactured part. In this study, a comparison of new and used Ti-6Al-4V powder characteristics was made. The comparison includes morphology, size distribution, as well as monotonic tensile and fatigue behavior of fabricated specimens. Conclusions and suggestions on powder recycling are made. Results indicate that the powder particle size distribution (PSD) becomes narrower and the morphology of the particles change with recycling. However, no comparable effect was observed on the monotonic tensile and fatigue behavior of the AM as-built Ti-6Al-4V specimens.


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