Ti alloys are widely used in aerospace and biomedical fields due to their high mechanical properties under severe loading. Interest in additively manufactured Ti6Al4V has increased, but further research is needed to fully characterize their properties. This work compares the effects of surface properties, internal defects, microstructure, hardness, and Hot Isostatic Pressing (HIP) or Vacuum Heat Treatment (VHT) on the fatigue behavior of Ti6Al4V produced by Selective Laser Melting (SLM) and Electron Beam Melting (EBM). Printing parameters and post-processing were optimized to achieve high density and minimal porosity, providing a solid basis for realistic fatigue comparisons. Samples were characterized in terms of microstructure (optical microscopy and SEM), mechanical properties (hardness mapping), surface texture (confocal microscopy), and internal defects (image-based analysis). Uniaxial fatigue limits were determined by a Dixon-Mood staircase method, and failed specimens were analyzed for fracture surfaces and defect areas. Applied load on flaws was evaluated to identify root causes of fatigue failure. Results showed that fatigue of as-printed samples is governed by surface roughness, while machined specimens are controlled by internal defect size. Machining increased the fatigue limit roughly threefold, and HIP further improved it by 10–20% by reducing internal porosity. In conclusion, with properly optimized melting parameters, both EBM and SLM produce similar mechanical performance at comparable roughness, supporting their use for structural components.
Sordetti et al. (Wed,) studied this question.