Effect of laser scan strategy on microstructural and tensile

characteristics of Ti-6Al-4V prepared by DMLS Route

Abstract

Metal additive manufacturing, specifically direct metal laser sintering (DMLS), has
made impressive strides and is currently predominant in the mechanical and manufacturing
fields. Multiple research examinations have confirmed that the build orientation utilized in
additive manufacturing (AM) significantly impacts mechanical properties. This study
examined how various Scan Orientation Strategies (SOS) affected the microstructures and
mechanical behavior of Ti-6Al-4V samples produced through DMLS. The samples were
classified as 1, 2, and 3 based on their SOS. The findings indicated that sample 1
demonstrated a higher Ultimate Tensile Strength (UTS) of 1250 Mpa, which was roughly
18.30% more than sample 3 and 9.66% more than sample 1, because of a more rapid rate of
segregation of elements. Sample 3 showcased a 25% higher percentage elongation than
sample 2 and 11.5% greater than sample 1. Scanning Electron Microscope (SEM) and
Optical Microscope (OM) images were scrutinized to reinforce the samples' fractographies, ,
elemental segregation and columnar pattern growth. Samples 1 and 3's fractured surfaces
presented even fracture and equaled failures with deep dimples, while sample 2's fractured
surface displayed an intermetallic arrangement that was brittle with less plastic deformation.

Keywords: Additive Manufacturing, Direct Metal Laser Sintering, SEM, UTS, scan strategy

Introduction

Additive Manufacturing (AM) is increasingly being used in personalized and precision

medicine to create customized medical devices and implants that are tailored to individual
patients. Direct Metal Laser Sintering (DMLS) is a specific type of AM process that uses a high-
powered laser to selectively fuse metal powders together to create a three-dimensional object.
The process starts with a three-dimensional Computer-Aided Design (CAD) model of the desired
final product. The CAD model is then sliced into multiple thin layers, which are used as the basis
for the additive manufacturing process. The DMLS has been growing in popularity in a variety
of industries, including aerospace, biomedical engineering, and automotive, among others. Its
ability to create strong, complex, and lightweight parts with minimal material waste makes it an
attractive option for many biomedical applications. There has been a significant increase in
demand for advanced materials in biomedical engineering, particularly in the field of orthopedic
reconstruction procedures. This demand has arisen from various factors, such as the need to
address deformities resulting from trauma or aging, as well as the growing number of elderly
individuals who require such procedures. As a outcome, there was a surge in the enlargement of
innovative materials and technologies that can enhance the safety and efficacy of orthopedic
implants, as well as reduce recovery times and improve patient outcomes. Over time, there has
been significant interest in metallic implants, with stainless steel, cobalt, and titanium alloys
being commonly used due to their desirable mechanical properties, biocompatibility, and
resistance to corrosion. One advantage of stainless steel is its ability to resist corrosion in harsh
environments due to its high chromium content, which enables the formation of self-healing and
corrosion-resistant oxide films. There are various types of stainless steel, with austenitic stainless
steel being the most commonly used for implant fabrication due to its excellent mechanical
properties and corrosion resistance. The Ti-6Al-4V, a titanium alloy with outstanding
mechanical properties such as high specific strength, good stability, and corrosion resistance, has
broad applications in several industries. Nonetheless, its costly nature and difficult machinability
limit its utilization in traditional manufacturing techniques like forging and casting. The DMLS
technique is capable of producing intricate and intricate shapes, and has been investigated for the
production of custom-made titanium implants. Titanium and its alloys are extensively used in
dental implants and orthopedic due to their favorable mechanical characteristics, chemical
stability, biocompatibility, and high strength-to-weight ratio, as well as good corrosion
resistance. These materials have been fully adopted in the medical industry due to their ability to
meet the necessary requirements for implantable medical devices.
Numerous researchers have concentrated on some parameters, like the laser power, laser spot
diameter, nozzle speed, feed rate and hatch interspacing on Ti-6Al-4V alloy by examining the
impact of various parameters on the quality of the DMLT components. Banghi et al. examined
how the mechanical characteristics of Ti-6Al-4V alloy fabricated using the SLM method are
affected by the orientation of the build. Creating titanium parts horizontally and parallel to the
substrate in an as-built state has always been difficult. The findings from tensile testing revealed
that the maximum stress at which fracture occurred in the vertical as-built parts was below the
yield stress of the horizontal as-built parts, representing around 38% of the UTS. This was
observed in both the truly as-built condition and other conditions. Xu et al. determined the
impact of different annealing treatments on the microstructure, mechanical characteristics, and
corrosion characteristics of Ti-6Al-4V produced through DMLT. The study found that the
microstructure of the material changed significantly with annealing temperature and time,
resulting in improvements in the mechanical characteristics, like UTS, YTS and ductility. The
annealing treatment also enhanced the material's corrosion resistance, as evidenced by reduced
corrosion rates in simulated body fluid environments. Sui et al. evaluated the impact of build
orientation on the mechanical characteristics and corrosion behavior of Ti-6Al-4V produced
through SLM. The research found that the material's corrosion resistance was significantly
affected by the build orientation, with samples produced in the vertical orientation exhibiting
higher corrosion rates than those produced horizontally. Furthermore, the study found that the
UTS and ductility of the material were higher in the horizontal orientation, indicating that this
orientation provides better mechanical properties. The findings suggest that the selection of build
orientation is a crucial consideration when designing and fabricating Ti-6Al-4V parts through
SLS. Srinivasan et al. investigated the microstructure and mechanical characteristics of heat-
treated DMLS Ti6Al4V alloy. The samples were produced using a DMLS system and were
subjected to HT at different temperatures. The microstructure of the samples was studied using
scanning electron microscopy (SEM). The results showed that the heat treatment caused
significant changes in the microstructure, with the formation of a lamellar α + β structure. The
tensile and compression strength of the heat-treated samples increased significantly compared to
the as-built samples. Additionally, the ductility of the samples increased after heat treatment,
resulting in an improvement in the elongation at break. However, the samples showed some
degree of anisotropy, with the horizontal orientation exhibiting higher mechanical properties
than the vertical orientation. Mierzejewska examined the mechanical and microstructure
characteristics of a Ti6Al4V alloy produced using DMLS for use in biomedical applications. The
research analyzed the influence of different process parameters on the microstructure of the
material, such as laser power, scanning speed, and layer thickness, and how these parameters
influenced the material's mechanical properties. The study found that the material's
microstructure was strongly influenced by the process parameters, with the formation of acicular
α' martensite being favored under certain conditions. The mechanical properties of the material,
such as tensile strength, yield strength, and elongation, were found to be influenced by the
presence of α' martensite and the size of the grains. The research concluded that DMLS can be
used to produce Ti6Al4V alloys with good mechanical properties suitable for biomedical
applications, provided that the process parameters are carefully controlled to achieve the desired
microstructure and mechanical properties. Zhao et al. investigated the influence of scanning
strategy and building direction on the microstructure and corrosion behavior of 316L stainless
steel fabricated by selective laser melting (SLM). They used three different scanning strategies:
alternating, bidirectional, and unidirectional. The samples were built in three different directions:
horizontal, vertical, and diagonal. The microstructure and surface morphology of the samples
were characterized by scanning electron microscopy (SEM) and X-ray diffraction (XRD). The
outcomes revealed that the scanning strategy had a significant effect on the microstructure and
corrosion behavior of the samples. The alternating and bidirectional scanning strategies resulted
in a fine and homogeneous microstructure with a smaller grain size compared to the
unidirectional scanning strategy. The samples built with the alternating and bidirectional
scanning strategies also exhibited better corrosion resistance than those built with the
unidirectional scanning strategy. Mierzejewska et al. investigated the influence of internal
porosity, laser energy density and heat treatment on the mechanical characteristics of biomedical
Ti6Al4V alloy fabricated using DMLS technology. The performances exposed that the
mechanical characteristics of the samples were strongly influenced by the laser energy density
and internal porosity. The samples with higher energy density exhibited higher strength and
lower ductility compared to those with lower energy density. Additionally, the presence of
internal porosity significantly reduced the strength and ductility of the samples. Heat treatment
was found to improve the ductility of the samples, but it also led to a reduction in strength. The
study concludes that optimizing the laser energy density and minimizing internal porosity is
crucial in obtaining Ti6Al4V samples with optimal mechanical properties for biomedical
applications. Alsalla et al. studied the consolidation and mechanical properties of Ti-6Al-4V
samples produced using DMLT in different building orientations. The study focuses on the
relationship between microstructure and fracture toughness, which has not been extensively
studied before. The results showed that the samples had excellent density and rougher surfaces
parallel to the building direction. However, the mechanical characteristics varied with the change
in microstructure at different building directions, and samples exhibited brittle fractures due to
the presence of the martensitic phase caused by a high temperature gradient. Gushchina et al.
investigated the impact of different scanning strategies on the mechanical properties of Ti-6Al-
4V alloy fabricated by LDED. The study examines four different scanning strategies, and the
results reveal that the mechanical characteristics, including hardness, tensile strength, and
ductility, are affected by the choice of scanning strategy. In particular, some strategies result in
an increase in UTS, YTS but a decrease in ductility.

Based on a review of existing research, it is clear that the direction in which the laser scans
during additive manufacturing has a significant impact on the microstructure and mechanical
properties of the resulting parts. This can lead to anisotropy, which is a major drawback when
compared to traditionally manufactured products. This study aims to fill that gap by investigating
the impact of two scanning strategies on DMLSed Ti-6Al-4V alloy, including evaluating its
relative density, surface roughness, and tensile properties (as well as fractography).