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<p>Ensuring component interchangeability between additively manufactured parts requires an understanding of how machine calibration tolerances affect material performance. While existing research addresses sweeping parameter alterations, the subtle effects of daily environmental and machine fluctuations remain under-explored, particularly multi-variable shifts involving gas flow dynamics. This study fills this gap by evaluating how routine deviations in laser power, scan speed, and gas flow rate impact the mechanical integrity and surface roughness of as-built Ti-6Al-4V Grade 23 specimens. Utilizing a systematic matrix of 21 tensile testing conditions and 9 surface roughness conditions, samples were produced using a Colibrium Additive M2 Series 5 laser powder bed fusion (L-PBF) printer with once-recycled and mixed once/twice-recycled powder. The mechanical properties examined include ultimate tensile strength (UTS), yield strength, and fracture strength. Part diameter and areal surface roughness were also examined. This study shows that printers experiencing fluctuations of ± 10% for laser power and scan speed and ± 5% for gas flow rate are capable of producing dimensionally similar components that have mean yield strength and ultimate tensile strengths varying by 2% or less.</p>

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Influence of minor print parameter variations on the mechanical properties of additively manufactured Ti-6Al-4V parts using laser powder bed fusion

  • 期刊论文

  • 发表日期：

    2026年7月23日

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  • Joshua Hall,
  • Marybeth Potter Radtke,
  • Jay Waterman,
  • Zahed Siddique,
  • Yingtao Liu

摘要

Ensuring component interchangeability between additively manufactured parts requires an understanding of how machine calibration tolerances affect material performance. While existing research addresses sweeping parameter alterations, the subtle effects of daily environmental and machine fluctuations remain under-explored, particularly multi-variable shifts involving gas flow dynamics. This study fills this gap by evaluating how routine deviations in laser power, scan speed, and gas flow rate impact the mechanical integrity and surface roughness of as-built Ti-6Al-4V Grade 23 specimens. Utilizing a systematic matrix of 21 tensile testing conditions and 9 surface roughness conditions, samples were produced using a Colibrium Additive M2 Series 5 laser powder bed fusion (L-PBF) printer with once-recycled and mixed once/twice-recycled powder. The mechanical properties examined include ultimate tensile strength (UTS), yield strength, and fracture strength. Part diameter and areal surface roughness were also examined. This study shows that printers experiencing fluctuations of ± 10% for laser power and scan speed and ± 5% for gas flow rate are capable of producing dimensionally similar components that have mean yield strength and ultimate tensile strengths varying by 2% or less.