The Influence of Dimensions and Powder Recycling on the Roughness and Mechanical Properties of Ti-6Al-4V Parts Fabricated by Laser Powder Bed Fusion

Powder bed fusion technology has undergone a remarkable amount of development in recent years in the field of medical implants due to the advantages associated with it. In many implant applications that demand loads in parts with a high degree of roughness and small dimensions, the mechanical properties, especially fatigue properties, play a key role in the success of the implants. One of the most used materials in this field is Ti-6Al-4V. On the other hand, the high cost of titanium powders makes it necessary to search for suitable powder recycling strategies. In this work, the effects of dimensions and powder recycling on the roughness and the mechanical properties of cylinder specimens were obtained from tensile static and fatigue tests of Ti-6Al4V Extra-Low Interstitial (ELI) parts. Four types of specimens were fabricated by laser powder bed fusion (two dimensions (section diameters of 2 mm and 5 mm) with new powder and with recycled powder). Results show that the oxygen concentration increased with recycling. No significant effects of recycling were observed on the monotonic tensile strength specimens. However, specimens fabricated with recycled powder showed greater roughness, lower ductility, and lower fatigue strength than those fabricated with new powder. On the other hand, the 5-mm-diameter specimens showed slightly better fatigue behavior than the 2-mm-diameter ones.