Laser Powder Bed Fusion (LPBF) offers considerable lightweight potential compared to conventional manufacturing processes, when it is combined with topology optimization and the usage of lightweight materials like Ti-6Al-4V.
Real material properties of the manufactured part have to be well known especially in critical part areas to optimize material distribution based on the applications load path and, thus, to maximize weight reduction. To qualify new lightweight LPBF part applications especially in aerospace, test benches are used nowadays to consider the real material properties of the component, which can be highly inhomogeneous across the part. That is because variations in the thermal history during the LPBF process lead to heat accumulation or intrinsic heat treatment and, therefore, to microstructural changes.
An approach of a prediction model will be presented that allows the mechanical properties of complex geometries to be estimated based only on thermal simulation results. The model has been developed with linear correlations between mechanical test data of representative geometry samples and the simulated thermal history (transient thermal Ansys Workbench LPBF simulation). Geometry-dependent differences in the microstructure (acquired by SEM) are presented as well as first results of the novel correlation model and statements on the prediction accuracy. Finally, an outlook on future developments of the model will be given.