CoCr alloy processed by Selective Laser Melting (SLM): effect of Laser Energy Density on microstructure, surface morphology, and hardness

•Co28Cr6Mo SLM samples built with Laser Energy Density (LED) from 43 to 268 J mm−3.•In-depth characterization of top and lateral surfaces.•Comprehensive examination of microstructural defects resulting from SLM.•LED well correlated to surface quality, microstructural features and hardness.•Optimized range for high quality Co28Cr6Mo SLM parts: LED = 150−200 J mm−3.