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A Laser Powder Bed Fusion Inconel 718 produced with intentionally non‐optimized parameters is investigated to understand the role of defects and microstructure on the high‐cycle fatigue life. Samples from three built directions and three heat treatments were used for fatigue tests at room and 650°C under R=0.1. Printing orientation has a minor effect on fatigue life at both temperatures. Most samples failed from lack of fusion defects, carefully analyzed by scanning electron microscope (SEM) observations. Surface defect leads to transgranular fracture surface, while subsurface initiation leads to crystallographic fracture surface. S−N curves related to hot isostatic pressure condition shown that defects have higher influence at 20°C than at 650°C. Kitagawa diagrams are plotted for both temperatures to quantify the influence of defect size on fatigue limit. Natural cracks are observed at the surface in order to discuss the relative part of initiation life in the whole fatigue life. Highlights: Fatigue is governed by lack of fusion (LoF) ranging from 200 to 600 μmThe fatigue limit is higher at high temperature compared with ambient temperatureHot isostatic pressure (HIP) treatment improves the fatigue resistanceNatural crack initiated from LoF propagates in a very similar way compared with long crack [ABSTRACT FROM AUTHOR]

Laser powder bed fusion (LPBF) is an outstanding additive manufacturing (AM) technology that can enable both complicated geometries and desired mechanical properties in high-value components. However, the process reliability and cost have been the obstacles to the extensive industrial adoptions of LPBF. This work aims to develop a powder recycling procedure to reduce production cost and minimize process uncertainties due to powder degradation. We used a recycle index (R) to reuse Ti-6Al-4V powder through 10 production cycles. Using this recycle index is more reasonable than simply replying on recycle numbers as it incorporates the powder usage history. A recycling procedure with simple virgin powder top-up can effectively mitigate powder degradation and maintain stable powder properties, chemical compositions, and tensile properties. The experimental finding points to a sustainable recycling strategy of Ti alloy powders with minimal material waste and without noticeable detriment to observed mechanical performance through LPBF production cycles. [ABSTRACT FROM AUTHOR]

The sliding behavior of two titanium alloys processed by laser powder bed fusion, with and without heat treatment, was investigated alongside two as-received conventionally-processed versions of these alloys. These samples presented a wide range of microstructures often encountered in Ti alloys. Oxidative, abrasive and adhesive wear always occurred when sliding against steel. However, wear rates were similar regardless of the friction and hardness if material removal mainly occurred through abrasion and/or adhesion. Martensitic phases decomposed during sliding while nano-crystalline grains enhanced oxidative wear which reduced friction. With a stable nanocrystalline microstructure that confers ultrahigh hardness, wear rate and friction can be substantially reduced by promoting oxidative over abrasive or adhesive wear. • Dry sliding of two conventionally- and LPBF-processed Ti alloys was investigated. • A nano-crystalline microstructure enhances oxide formation which reduces friction. • α′ or α″ is unstable in the presence of frictional heat and oxygen diffusion. • A stable ultrahard nanocrystalline microstructure can reduce both wear and friction. • This microstructure promotes oxidative wear and minimizes adhesion/abrasion. [ABSTRACT FROM AUTHOR]

In this study, the tribological properties of an AlSi10Mg alloy that was fabricated using laser powder bed fusion, an additive manufacturing technique, was investigated in both the as-built (but stress-relieved) and T6-treated condition. The stress-relieved condition consists of elongated Al grains and a dendritically-arranged nano-crystalline Si-phase. T6 treatment, a conventional heat treatment for cast AlSi10Mg alloys, caused this Si phase to dissolve, re-precipitate and coarsen, which resulted in a loss of hardness, toughness and strength. Dry sliding wear tests were conducted against both a bearing stainless steel and a much harder SiC, and with the sliding direction either perpendicular or parallel to the building direction. In almost all conditions it was found that the T6 treatment either had no statistically significant effect on the wear rate or was detrimental. • In the stress-relieved condition, the wear performance is isotropic. • Wear anisotropy occurred in the T6 condition. • The wear rate against steel is more severe than against SiC. • Frictional response is not necessarily indicative of wear performance. • T6 treatment is generally not recommended for sliding wear performance. [ABSTRACT FROM AUTHOR]