Effect of Layer Thickness and Particle Size Distribution on the Microstructure and Properties of Ti6Al4V Processed by Laser Powder Bed Fusion

Book chapter, 2025

The technological advancements in laser powder bed fusion (PBF-LB/ L-PBF) processing has led to the potential in utilizing larger powder bed layer thicknesses aimed at increasing the productivity. Moreover, by increasing the layer thickness, coarser powder particle size distribution (PSD) may be employed, further improving cost-effectiveness of the process. This drives the shift towards a more sustainable process chain, while reinforcing the business cases in additive manufacturing (AM). In this study, the effect of larger layer thickness (i.e., 90 µm) using recommended PSD of 15 to 45 µm, as well as feedstock powder with a coarser PSD (i.e., 45 to 90 µm) on the surface characteristics, heat treated microstructure, and mechanical properties of Ti64 components is evaluated. The results were then compared with that of 30 and 60 µm layer thicknesses, using a standard PSD of 15 to 45 µm.