Influence of porosity on the fatigue life of laser powder bed fusion–produced Ti6Al4V

Abstract

This work explores the fatigue life implications of porosity, microstructure, and the presence of residual stresses of laser powder bed fusion (LPBF)–produced Ti6Al4V. In particular, this study considers stress vs cycles to failure and its link to porosity levels, the underlying microstructure, and the presence of residual stresses. It is shown that both porosity and microstructure play the significant role that adversely affect fatigue life. However, neither play a leading role, and the combination of the two that govern the fatigue life performance of LPBF-produced Ti6Al4V. Residual stresses are shown to have a lesser influence.