Selective laser melting of Ti6Al4V alloy: effects of process parameters at constant energy density on mechanical properties, residual stress, microstructure and relative density

Selective laser melting is a production method that results in a large amount of residual stress due to high cooling rates and high thermal gradients. Although there are many studies examining the effects of process parameters on residual stress or mechanical properties in the literature, there are a few studies investigating the effects of changing laser power and scanning velocity (exposure time) at constant energy density on residual stress or mechanical properties and these studies have different results. This is a comprehensive study in this field that includes detailed comparisons with the results of similar studies in the literature. In this study, firstly specimens were produced at different process parameters and it was tried to find the process parameters that will obtain the highest relative density among the trials. Then at the constant energy density (85.0 J mm(-3)), which the maximum density has been obtained the effects of changing laser power and scanning velocity on residual stress, mechanical properties, microstructure and relative density were investigated. It was observed that at constant energy density, increasing or decreasing laser power and scanning velocity did not increase or decrease residual stress, tensile strength, % elongation and relative density monotonously.