Effect of a helium gas atmosphere on the mechanical properties of Ti-6Al-4V alloy built with laser powder bed fusion: A comparative study with argon gas

In metal additive manufacturing, the microstructures and associated mechanical properties of metal specimens can be controlled over a wide range. Although process parameters are considered important in the fabrication of functional parts, the effect of atmospheric gas has not been comprehensively documented. In laser powder bed fusion (LPBF), gas flow is used to eliminate fumes generated by laser irradiation. Simultaneously, the gas removes heat from the laser-irradiated part, which is exposed to high temperature. In this study, we investigated the capacity of helium as an alternative to argon, which is conventionally used as the LPBF atmosphere gas. He has a higher thermal conductivity and lower gas density than Ar, which may result in enhanced heat removal from the Ti-6Al-4V alloy during fabrication. Numerical simulations suggest a greater cooling rate under He flow. Further, the material built under He flow contained finer alpha' martensite grains and showed improved mechanical properties compared to those fabricated under Ar flow, despite the identical laser irradiation conditions. Thus, He gas is advantageous in LPBF for fabricating products with superior mechanical performance through microstructural refinement, and this is a result of its capacity for cooling and fume generation inhibition. Therefore, this study reveals the importance of the choice of atmospheric gas because of its effects on the characteristics of metallic specimens fabricated using LPBF.