Dimensional deviations in Ti-6Al-4V discs produced with different process parameters during selective laser melting

When manufacturing complicated products where both material and design play a role, especially thin and curved components, it is difficult to maintain accurate dimensions in Selective Laser Melting. Considering these difficulties, this article presents the dimensional errors in the fabrication of Ti-6Al-4V discs and their thermomechanics during manufacturing. Various combinations of laser processing parameters were used to fabricate the 2.00 mm thick discs with a diameter of 5.70 mm. It was found that the thickness shortened and the round shape changed to an oval shape for most of the discs. The thickness decreased along the build-up direction from the bottom to the top and formed a taper that increased with increasing energy density (ED). The horizontal diameter of the discs changed slightly, while the vertical diameters changed remarkably with increasing ED. On the other hand, reducing the laser power resulted in a reduction of the roundness error, while it caused a reduction of the thickness. The hatch spacing significantly affected the volume of the melt pool and caused a change in the vertical diameter. The central part of the curved surface of the discs became concave and the concavity increased due to the increasing ED.