Laser Power and Scan Speed Effects on Density, Surface Quality, and Mechanical Properties of PBF-LB/M Ti-6Al-4V

This study investigates how laser power–scan speed combinations influence densification, surface quality, and mechanical performance of Ti-6Al-4V parts fabricated by Powder Bed Fusion–Laser Beam/Metal (PBF-LB/M) on a DMG MORI LASERTEC 30 SLM (2nd generation) system. A parametric matrix was explored by varying laser power (150–400 W) and scan speed (0.9–1.4 m·s−1) at constant layer thickness and hatch spacing, deliberately omitting contour exposure to isolate core scan effects. A stable processing window was identified (250–300 W; 0.9–1.0 m·s−1) corresponding to ~50–60 J·mm−3 volumetric energy density (VED) achieved at 99.5% with residual porosity of 0.1–0.3%. In this regime, as-built roughness measured Ra = 4–6 µm on top surfaces and Ra = 15–17 µm on side surfaces. Mechanical testing in the as-built showed ultimate tensile strength (UTS) = 1150–1180 MPa and offset yield strength (YS0.2) = 955–994 MPa, with elongation up to 6.7%. Hardness increased from 220 HV to 360 HV as densification improved. Notably, similar VED values derived from distinct power–speed combinations resulted in divergent outcomes, confirming that VED alone does not uniquely predict quality. Comparative benchmarks from the literature data highlight the performance achieved. The resulting process–property map provides a practical reference for parameter optimization, reproducibility evaluation, and transferability across platforms.