IN-SITU ALLOYING OF TI6AL4V-x%CU STRUCTURES BY DIRECT METAL LASER SINTERING

Abstract

The formation of in-situ Ti6Al4V-x%Cu (1%, 3% and 5% Cu) alloy structures by Direct Metal Laser Sintering (DMLS) for application in medical implants was investigated. Ti6Al4V (ELI) powder was mixed with pure Cu powder of similar particle size distribution. Optimal process parameters were established for in-situ alloying of Ti6Al4V-x%Cu to form dense parts with suitable microstructural and surface quality. Process parameters such as laser power, scanning speed, hatch distance and layer thickness directly affect the surface quality and part density. Firstly, single track formation was studied at different scanning speeds for 170 W and 340 W laser powers. The effect of laser power and scanning speed on the track width and shape was described. Secondly, the surface roughness and single layer morphology were considered.