An Investigation of Process Parameter Modifications on Additively Manufactured Inconel 718 Parts

Additive manufacturing (AM) allows for the fabrication of complex parts via layer-by-layer melting of metal powder. Laser powder-bed AM processes use a variety of process parameters including beam power, beam velocity, and hatch spacing to control melting. Alterations to these parameters have often been attempted to reduce porosity, for example, but less work has been done to on comprehensive effects of process parameter modifications. This study looks at the effects of altering these parameters on microstructure, porosity, and mechanical performance of Inconel 718. The results showed that process parameter modifications that result in porosity formation can significantly reduce fatigue life, while microstructure changes were minimal and had little effect on tensile properties. The precipitate structure was not found to be changed significantly. These results can inform future process parameter modifications, as well as heat treatments to optimize mechanical properties.