Micro-CT-based improvement of geometrical and mechanical controllability of selective laser melted Ti6Al4V porous structures

Highlights: → Selective laser melting as a production tool for porous Ti6Al4V structures. → Significant mismatch between designed and as-produced properties. → Decreasing mismatch using a micro-CT-based protocol. → Mismatch of pore size decreased from 45% to 5%. → Increased morphological controllability increases mechanical controllability. - Abstract: Despite the fact that additive manufacturing (AM) techniques allow to manufacture complex porous parts with a controlled architecture, differences can occur between designed and as-produced morphological properties. Therefore this study aimed at optimizing the robustness and controllability of the production of porous Ti6Al4V structures using selective laser melting (SLM) by reducing the mismatch between designed and as-produced morphological and mechanical properties in two runs. In the first run, porous Ti6Al4V structures with different pore sizes were designed, manufactured by SLM, analyzed by microfocus X-ray computed tomography (micro-CT) image analysis and compared to the original design. The comparison was based on the following morphological parameters: pore size, strut thickness, porosity, surface area and structure volume. Integration of the mismatch between designed and measured properties into a second run enabled a decrease of the mismatch. For example, for the average pore size the mismatch decreased from 45% to 5%. The demonstrated protocol is furthermore applicable to other 3D structures, properties and production techniques, powder metallurgy, titanium alloys, porous materials, mechanical characterization, tomography.