Enhancing Quality Assurance Through Density and Surface Roughness Analysis of 3D-Printed Ti6Al4V Parts Based on Volumetric Energy Density Mechanism

The performance of 3D-printed products via laser powder bed fusion (LPBF) process is influenced by various processing parameters. This study focuses on the effect of volumetric energyEnergy density (VED) produced using four major LPBF parameters: laser power, scan speed, scan spacing and layer height. DOE Taguchi L9 is utilized in generating nine parameter sets for fabricating cubic samples using the RenAM 500E printing machine. The laser power ranges from 180 to 220 W, scan speed from 1000 to 1500 mm/s, scan spacing from 55 to 65 µm, and layer height remains constant at 40 µm. Post printing, all samples undergo annealing at 935 °C for 8 h with a controlled heating and cooling rate to eliminate residual stressesStress. The density and surface roughness of the Ti6Al4V samples are analyzed. Lower VED was found to produce samples with higher density and lower surface roughness. Based on the results, the parameter set with a VED value of 61.11 J/mm3 resulted in the highest quality samples, exhibiting a density of 99.16% and a surface roughness of 11.16 µm. This parameter set holds great potential for various applications where high density and smooth surface finish are crucial for optimal performance.