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Additive manufacturing has many process variables and requires additive process optimization. Line energy and scan speed are the main process variables. The objective of this work aims to investigate the effect of changes in line energy and scan speed among the process variables on the mechanical and fatigue properties of the Ti6Al4V specimens fabricated by electron beam additive manufacturing method. The size of the pore inside the specimen was 40~60 μm with the exception of the condition of 0.2 kJ/m, and the specimen with poor fusion of more than 100 μm and gas pore was found to have lower room temperature tensile and fatigue properties compared to the optimal process conditions. As line energy increased, strain hardening occurred, and yield strength and tensile strength increased. The EL:0.3 kJ/m and 800 mm/s condition is a process condition that shows no defects such as unmelted powder and poor fusion, and it represents the best fatigue strength of 400 MPa. The fatigue strength of the specimen performed with hot isostatic pressing after additive manufacturing was measured at 550 MPa, an increase of 150 MPa, which resulted in high fatigue strength enhancement. The crack initiation site and propagation behavior were analyzed by observing the fatigue fracture section of the specimen according to the line energy.

Effect of Line Energy Conditions on Mechanical and Fatigue Properties of Ti6Al4V Fabricated by Electron Beam Additive Manufacturing