Numerical, Mechanical, and Metallurgical Investigation of an Innovative Near Net Shape Titanium Selective Laser Melting Engine Component and Comparison with the Conventional Forged One

Selective laser melting (SLM) can be used to manufacture near net shape (NNS); the main benefits are a remarkable weight reduction, lower environmental impact, opportunity integrate some functions, and an improvement of performances. The current article covers development Ti6Al4V NNS engine component produced by SLM. Finite element analyses relevant operating conditions performed reach topological optimization part. target is reduction keeping same safety achieved 45% 15% with respect steel titanium forging replacing original “H” section SLM multibranch structure. Other manufacturing connecting rod (conrod) into two separate parts, avoiding difficult machining cap from body integration conformed cooling channels conrod. Then, components mechanical metallurgical properties investigated compared hot ones. Both macrostructures present equiassic isotropic behavior due heat treatment transformation. No defects observed for both technologies. verified aligned design targets.