Productivity enhancement of laser powder bed fusion using compensated shelled geometries and hot isostatic pressing, Ti-6Al-4V

In laser powder bed fusion (L-PBF), hot isostatic pressing (HIP) improves mechanical and fatigue properties by increasing density and enhancing microstructure. HIP ensures defect-free material, crucial for aerospace applications. Recent studies show HIP can consolidate intentionally-unmelted interior powder in L-PBF parts, reducing production times. This study investigates using HIP to consolidate interior sections of test coupons, finding that shell thickness affects shrinkage ratio. Compensatory designs offset shrinkage or distortion during HIP, with mechanical evaluation showing equivalent tensile performance to fully dense printed parts. This enables faster build rates with HIP consolidation.