Effect of LPBF Processing Parameters on Inconel 718 Lattice Structures: Geometrical Characteristics, Surface Morphology, and Mechanical Properties

Ghanadi, Nahal; Son, Kwangtae; Alvarado, Marco; Yang, Seongun; Kao, Hsin-Mei; Chang, Chih-Hung; Paul, Brian K.; Pasebani, Somayeh

doi:10.1016/j.matdes.2025.113864

Effect of LPBF Processing Parameters on Inconel 718 Lattice Structures: Geometrical Characteristics, Surface Morphology, and Mechanical Properties

Journal Article · Fri Mar 28 00:00:00 EDT 2025 · Materials & Design

DOI:https://doi.org/10.1016/j.matdes.2025.113864· OSTI ID:3003894

Ghanadi, Nahal ^[1]; Son, Kwangtae ^[1]; Alvarado, Marco ^[1]; Yang, Seongun ^[1]; Kao, Hsin-Mei ^[2]; Chang, Chih-Hung ^[2]; Paul, Brian K. ^[1]; Pasebani, Somayeh ^[1]

Oregon State University, Corvallis, OR (United States); Advanced Technology and Manufacturing Institute (ATAMI), Corvallis, OR (United States)
Oregon State University, Corvallis, OR (United States)

Laser Powder Bed Fusion (LPBF) enables the additive manufacturing of complex lattice structures. However, the fabrication of lattice structures via LPBF poses challenges in achieving the intended geometrical accuracy due to their inherent complexity. This study investigates the effects of LPBF processing parameters, specifically laser power and scanning speed, on the geometrical characteristics, surface quality, and mechanical behavior of Inconel 718 lattices structures. The results reveal that processing parameters required for the fabrication of near-full dense structures do not translate effectively to lattice configurations, as variations in energy input influence lattice geometry and surface quality. In this work, strut thickness, open-pore size, open-cell porosity, and surface roughness were measured, and the mechanical properties of the lattices were evaluated under shear loading. The findings indicate that lower energy inputs, achieved by reducing laser power and increasing scanning speed, yield porous structures but lead to mechanical degradation. In contrast, high energy inputs lead to lattices with enhanced strength but result in undesirable open-pore blockage and dimensional inaccuracies. These findings provide insights into tailoring LPBF parameters for dimensional accuracy in lattices and correlating the processing parameters to mechanical performance and surface roughness.

View Accepted Manuscript (DOE)

Research Organization:: Oregon State University, Corvallis, OR (United States)

Sponsoring Organization:: USDOE Office of Energy Efficiency and Renewable Energy (EERE), Office of Sustainable Transportation. Bioenergy Technologies Office (BETO)

Grant/Contract Number:: EE0009261

OSTI ID:: 3003894

Journal Information:: Materials & Design, Journal Name: Materials & Design Vol. 253; ISSN 0264-1275

Publisher:: Elsevier BVCopyright Statement

Country of Publication:: United States

Language:: English

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