A Defect Size Distribution Model for Durability Analysis of Selective‐Laser‐Melted Alloys

The selective laser melting (SLM) technology finds increasing application in the manufacturing of complex engineering components. The micropore defects formed during the SLM process have significant negative effects on fatigue performance of SLM alloys. This paper presents a probabilistic model of defect size distribution established based on the formation of laser melting defects and their evolution process. Scanning electron microscope (SEM) and computed tomography (CT) scanning were employed to observe and measure the microstructures of totally 33 SLM‐manufactured TiB 2 ‐Al reinforced specimens, yielding data on 9,226 micropore defects. The results show that the goodness‐of‐fit () for the TiB 2 ‐Al alloy, Ti 6 Al 4 V alloy, and AlSi 10 Mg alloy samples is consistently around 0.95, validating the effectiveness and rationality of the proposed model.