Optimization of laser powder bed fusion parameters for Ti-Ag parts from silver-coated Ti powders via response surface methodology

Purpose The purpose of this study to investigate the effects of laser power, hatch spacing and layer thickness on the mechanical and physical properties of the novel Ti-Ag samples produced by selective laser melting (SLM) using electroless silver coated Ti powder. Design/methodology/approach A RSM-based experimental design was used to assess the impact of various parameters on the performance of the system. The laser power, the hatch spacing and the layer thickness were evaluated at three distinct levels of 75–87.5–100 W, 40–60 - 80 µm and 20–30 - 40 µm, respectively. Findings According to the results, increasing laser power improves the material properties, while increasing layer thickness has negative effects. Hatch spacing showed a positive effect up to a certain level, but relative density and hardness decreased at higher hatch spacing values. The highest relative density was 95.61%, and the lowest was 88.59%. The highest hardness was measured at 302.53 HV, while the lowest was 204.53 HV. The highest electrical conductivity value was 1.9 IACS%, and the lowest was 1.1 IACS%. Originality/value As a result of the optimization studies, 100 W laser power, 80 µm hatch spacing and 20 µm layer thickness were determined as the most suitable SLM parameters. This study provides novel insights into the processing of electroless silver-coated Ti powders via SLM, demonstrating its potential for fabricating Ti-Ag composites with tailored properties.