X-CT defect-informed process optimization of PBF-LB Ti-15wt.%Nb alloy from elemental powder blends

Laser beam powder bed fusion (PBF-LB) of Ti-Nb elemental powder blends requires simultaneous control of density, pore defects, feedstock quality, and mechanical performance. This study develops an X-CT defect-informed process-parameter-set optimization workflow for PBF-LB Ti-15wt.%Nb. Forty-one parameter sets, 18 tensile conditions, 13 training and 2 confirmation X-CT datasets, and three confirmation builds were evaluated. Repeated-CV low-capacity regression and response-surface analysis characterized the density response, while Dmax strongly correlated with elongation. A six-objective desirability function identified parameter set 26#, which was reproduced in a separate C1 confirmation build with high density, strength, ductility, and low pore risk.