Parameter optimization for Ti-47Al-2Cr-2Nb in selective laser melting based on geometric characteristics of single scan tracks

A rapid method for parameter optimization for Ti-47Al-2Cr-2Nb powder in selective laser melting (SLM) based on melt pool characterizations is developed. The laser power and scanning speed are selected through the surface morphologies of single tracks to fabricate the high-density samples. The influences of the parameters on sectional geometric characteristics (width, height, depth, bulge area, penetration area and dilution) are analyzed by linear regression analysis, and the regression models are established to predict the geometric characteristics of single tracks. An inappropriate combination of process parameters can cause material evaporation and the melt pool instability, leading to generation of cracking and balling, which will reduce the linear correlation. The loss of Al is also an important reference criterion for the optimization of the process parameters, so Al content measurements are conducted to validate evaporation during the SLM processing. The Al loss from single tracks varies from 5.73 to 0.32 at%. Applying optimal process parameters to the fabrication of TiAl parts result in densities ranging from 97.34% to 98.95%. However, more serious losses and an uneven distribution of Al in the fabricated samples are observed.