Dimensional errors in selective laser melting products related to different orientations and processing parameters

Abstract

This research has investigated the changes of dimensions with changes of the Energy Density (ED), processing parameters and build up direction wise of Ti-6Al-4V alloy products manufactured by the Selective Laser Melting (SLM) process. The selected processing parameters were laser power, scanning speed, and hatch spacing in several combinations, keeping the layer thickness constant during all three steps of the studies. Four orientations have been considered for a specimen to build up in different directions for each of the selected combinations of processing parameters. The SLM process is characterized by the high laser energy inputs into a metallic powder layer in a short interaction time that occurs several thermal related issues that significantly affect the shape and dimensions of the part. The results show that ED, as well as its processing parameters, have significant influences on the product's dimensions. The building orientation has a great impact on the dimensional accuracy.