Laser Powder Bed Fusion Parameters Optimization for Enhanced Mechanical Properties of EOS Co-Cr Dental Alloy

This research explores how variations in laser powder bed fusion (LPBF) parameters-laser power (<i>P</i>), scanning speed (<i>v</i>), and base plate preheating temperature (<i>ϑ</i>_p)-affect the mechanical properties of the EOS Co-Cr SP2 dental alloy. A central composite design (CCD) was used to optimize the process parameters. Mechanical testing focused on crucial properties for dental applications, including yield strength (<i>Rp</i>_0.2), elongation (<i>ε</i>), toughness (<i>KV</i>_a), and flexural strength (<i>R</i>_ms). Microstructural analysis was conducted using light and electron microscopy, while XRD identified microstructural phases. Statistical analysis (ANOVA, Scheffé post hoc test, α = 0.05) revealed significant effects of <i>P</i>, <i>v</i>, and <i>ϑ</i>_p on the mechanical properties. Response surface models (RSMs) were developed, and optimal parameters were determined to achieve maximum toughness and flexural strength. Maximum values were obtained with laser power above 205 W and base plate preheating at 310 °C. The mathematical model predicted toughness values with less than 5% deviation from experimental results, indicating high accuracy.