Process‐Informed Analysis of As‐Built Metal Additive Surface Features

Additive manufacturing (AM) technologies show potential for the development of functionally integrated lightweight designs, biomimetic structures and material savings. Typically, as‐built surfaces show powder particle agglomerations and re‐entrant features, leading to rough surfaces, which are associated with poor fatigue performance. To benefit from the full range of advantages with special focus on aerospace applications, critical features for crack initiation when subjected to fatigue loading need to be identified and mitigated. A first step towards achieving this goal is the surface texture characterisation based on the quantification of surface features. In this paper, selected areal height, functional and feature parameters from ISO 25178‐2:2022 are generated and process‐specific features are examined for as‐built AlSi7Mg0.6 from laser‐based powder bed fusion. A connection with the particle size distribution of the used powder is demonstrated. This direct incorporation of manufacturing variables into the characterisation of surface texture in metal AM is a novel approach in the field.