Investigating the variation of particle distribution and surface texture of top surfaces based on build position in laser powder bed fusion

Quality analysis of additively manufactured (AM) surfaces is complex, yet critical for determining the functionality of parts and technology improvement. To accurately assess the quality of AM parts, it is necessary to consider the industrial application of the technology. This study investigates the variation of accumulated particles on AM top surfaces as a function of build position. It also seeks to study the surface texture variation as a function of build position, focusing on a spatial bandwidth region larger than that of traditional AM surface features, such as weld tracks, to investigate surface tension effects. Ti-6Al-4V cubes were built in a three-by-three array in a single build with fixed processing parameters. Coherence scanning interferometry was used to capture the primary data of the as-built top surfaces of cubes. The ISO 25178-2 methodology was used to extract the S-L surfaces, using the filtration methods defined in ISO 16610-21. The number of particles, coverage, and density were obtained by averaging over five repeated measurements in five different areas on the top surfaces. Particle distribution and surface texture analysis showed a trend from one location to another across the build, which is discussed according to the process variations.