In laser powder bed fusion (LPBF), also known as selective laser melting (SLM), the feedstock powder and processing parameters affect the properties of additively manufactured parts. Limited... Show moreIn laser powder bed fusion (LPBF), also known as selective laser melting (SLM), the feedstock powder and processing parameters affect the properties of additively manufactured parts. Limited research has been conducted on non-spherical Ti6Al4V feedstock powder prepared by Hydride-Dehydride process. Significant progress in metal powder additive manufacturing (AM) requires the inter-linking of multiple variables, which includes starting materials, process settings, and post-treatment to achieve desired resultant properties. Owing to the rapid emergence of metal 3D-printing, process-property relationships, and appropriate post-treatment conditions have not been as extensively characterized as for conventional materials, thus requiring significant attention. Over the years, spherical powders were used in powder bed AM machines and there have been various concerns related to powder as well as processing parameters leading to defects formation, poor part quality, and unsatisfactory performance. It is critical to keep the cost of manufacturing low for large-scale production which results in significant interest in low-cost powder, making it vital to understand the effect of microstructural defects on corrosion behavior. Recently, economical powder attracted attention in AM, thus, making it is necessary to understand the role of possible microstructural defects on corrosion behavior. In powder bed additive manufacturing, feedstock and processing affect final microstructure and properties of the 3D printed parts. While numerous studies have evaluated 3D-printing of spherical powder, very limited research has examined the processing of the non-spherical feedstock. In this research, parts are manufactured by SLM of hydride-dehydride (HDH) Ti6Al4V powder. heat treatment and hot isostatic pressing are applied on SLM parts. The microstructures, potentiodynamic curves, and electrochemical impedance spectroscopy are characterized for SLM processed, heat treated, and hot isostatically pressed HDH Ti6Al4V specimens. Results indicate although the as-built specimen has anisotropic microstructure (i.e., lamellar α + acicular α’ + β phases), the heat treatment and hot isostatic pressing result in homogenized grain structures and enhanced corrosion behavior. Results indicate that type of constituent phase, grain size, and morphology directly determine corrosion resistance. This research is beneficial for the manufacturing of low-cost titanium alloys. In the current research, we evaluate non-spherical powder processing by hydride-dehydride (HDH) method and selective laser melted in powder bed AM machine followed by heat treatment and hot isostatic pressing to alter microstructure and electrochemical behavior. If successful, the usage of non-spherical morphology in conjunction with the newer powder dispensing method of double smoothing will enable remarkable improvements in the quality and performance of additively manufactured products. This method will also cut down costs associated with a greener powder production method and enhance the fabrication rate. It is a well-established fact that corrosion behavior is drastically affected by heterogeneous microstructure and defects. Thus, it is paramount to conduct a systematic study on the role of processing parameters and post process heat treatment, which can enhance our understanding of possible defect formation in micro and macro scale and their impact on electrochemical behavior. Show less
