Efficient optimization framework for L-PBF fatigue enhanced Ti6Al4V lattice component

Industries today face challenges in incorporating metallic additively manufactured lattice structures in critical components subjected to fatigue loading. This work explores the relationship between fatigue properties and the printing orientation of Laser-Powered Bed Fusion (LPBF) lattice structures. This relation is at the base of a cost-effective and time-efficient optimization workflow able to determine the optimal lattice printing orientation for improved fatigue life. Fatigue resistance is tested under uniaxial conditions on miniaturized specimens that mimic the lattice sub-unit elements: struts and nodes. The collected data is used as input for the optimization algorithm to determine the specimen orientation that maximizes fatigue life. The optimized specimens are manufactured, tested under three-point-bending conditions, and analysed using metrological x-ray computed tomography to verify the improvement. The proposed workflow is able to produce a 24 % increase in specimen fatigue life by simply adjusting the orientation on the printing plane.