Numerical and Experimental Assessment of the Effect of Residual Stresses on the Fatigue Strength of an Aircraft Blade

The work presents the results of numerical fatigue analysis of a turbine engine compressor blade, taking into account the values of initial stresses resulting from surface treatment-shot-peening. The values of the residual stresses were estimated experimentally using X-ray diffraction. The paper specifies the values of the residual stresses on both sides of the blade and their reduction due to cutting through the blade-relaxation. The obtained values of the residual stresses were used as initial stresses in the numerical fatigue analysis of the damaged compressor blade, which was subjected to resonant vibrations of known amplitude. Numerical fatigue ε-N life analysis was based on several fatigue material models: Manson’s, Mitchell’s, Baumel-Seeger’s, Muralidharan-Manson’s, Ong’s, Roessle-Fatemi’s, and Median’s, and also on the three models of cyclic hardening: Manson’s, Xianxin’s, and Fatemi’s. Because of this approach, it was possible to determine the relationship between the selection of the fatigue material ε-N model and the cyclic hardening model on the results of the numerical fatigue analysis. Additionally, the calculated results were compared with the results of experimental research, which allowed for a substantive evaluation of the obtained results. These results are of great scientific and practical importance. The problem of determining the fatigue life of blades with defects operating under resonance vibrations is one of the original tasks in the field of fracture mechanics and experimental mechanics. The results obtained are of great importance in the aviation industry and can be used during engine maintenance and inspections to assess the suitability of blades with defects in terms of the needs of further work. This aspect of engineering maintenance is of great importance from the aircraft safety point of view.     

Cyclic Deformation Induced Residual Stress Evolution and 3D Short Fatigue Crack Growth Investigated by Advanced Synchrotron Tomography Techniques

Diffraction and phase contrast tomography techniques were successfully applied to an austenitic–ferritic duplex stainless steel representing exemplarily a metallic material containing two phases with different crystal structures. The reconstructed volumes of both phases were discretized by finite elements. A crystal plasticity finite-element analysis was executed in order to simulate the development of the experimentally determined first and second order residual stresses, which built up due to the manufacturing process of the material. Cyclic deformation simulations showed the single-grain-resolved evolution of initial residual stresses in both phases and were found to be in good agreement with the experimental results. Solely in ferritic grains, residual stresses built up due to cyclic deformation, which promoted crack nucleation in this phase. Furthermore, phase contrast tomography was applied in order to analyze the mechanisms of fatigue crack nucleation and short fatigue crack propagation three-dimensionally and nondestructively. The results clearly showed the significance of microstructural barriers for short fatigue crack growth at the surface, as well as into the material. The investigation presented aims for a better understanding of the three-dimensional mechanisms governing short fatigue crack propagation and, in particular, the effect of residual stresses on these mechanisms. The final goal was to generate tailored microstructures for improved fatigue resistance and enhanced fatigue life.     

Low Cycle Fatigue Life Assessment Based on the Accumulated Plastic Strain Energy Density

The accumulated plastic strain energy density at a dangerous point is studied to estimate the low cycle fatigue life that is composed of fatigue initiation life and fatigue crack propagation life. The modified Ramberg–Osgood constitutive relation is applied to characterize the stress–strain relationship of the strain-hardening material. The plastic strain energy density under uni-axial tension and cyclic load are derived, which are used as threshold and reference values, respectively. Then, a framework to assess the lives of fatigue initiation and fatigue crack propagation by accumulated plastic strain energy density is proposed. Finally, this method is applied to two types of aluminum alloy, LC9 and LY12 for low-cycle fatigue, and agreed well with the experiments.     

The Effect of Baking Heat Treatment on the Fatigue Strength and Life of Shot Peened 4340M Landing Gear Steel

In this study, the effect of baking heat treatment on fatigue strength and fatigue life was evaluated by performing baking heat treatment after shot peening treatment on 4340M steel for landing gear. An ultrasonic fatigue test was performed to obtain the S–N curve, and the fatigue strength and fatigue life were compared. The micro hardness of shot peening showed a maximum at a hardened depth of about 50 μm and was almost uniform when it arrived at the hardened depth of about 400 μm. The overall average tensile strength after the baking heat treatment was lowered by about 80–111 MPa, but the yield strength was improved by about 206–262 MPa. The five cases of specimens showed similar fatigue strength and fatigue life in high cycle fatigue (HCF) regime. However, the fatigue limit of the baking heat treated specimens showed an increasing tendency rather than that of shot peening specimens when the fatigue life was extended to the very high cycle fatigue (VHCF) regime. The effect of baking heat treatment was identified from improved fatigue limit when baking heat was used to treat the specimen treated by shot peening containing inclusions. The optimum temperature range for the better baking heat treatment effect could be constrained not to exceed maximum 246 °C.     

Stress-Shot-Peened Leaf Springs Material Analysis through Nano- and Micro-Indentations

Heat-treated and shot-peened lightweight steels with demanding requirements for durability are applied in high-performance automotive leaf springs. Due to their heat-treatment they exhibit degraded properties in the surface-near area compared to the core. This area, which may extend until 300 μm from the surface to the core, experiences the highest bending stresses at operation. The microstructure in the surface and sub-surface layers determines the mechanical performance as well as the wear resistance. The present study refers to the material properties of a stress shot-peened 51CrV4 steel at various depths from the surface. The effect of the manufacturing process has been captured both by Vickers micro-hardness measurements and nanoindentation. The latter combined with a Fine Element Method (FEM)-based algorithm enables the determination of variations in the material’s stress–strain curves over the affected layers, which translate to internal stress changes. The nanoindentation technique has been applied here successfully for the first time ever on leaf springs. The combination of microstructural analysis, microhardness and nanoindentation captures the changes of the treated material, offering insights on the material characteristics, and yielding accurate elastoplastic material properties for local, layered-based analysis of the components’ mechanical performance at operational loading scenarios, i.e., in the framework of stress shot-peening simulation models.     

Fatigue Behavior of Linear Friction Welded Ti-6Al-4V and Ti-6Al-2Sn-4Zr-2Mo-0.1Si Dissimilar Welds

The use of joints fabricated from dissimilar titanium alloys allows the design of structures with local properties tailored to different service requirements. To develop welded structures for aerospace applications, particularly under critical loading, an understanding of the fatigue behavior is crucial, but remains limited, especially for solid-state technologies such as linear friction welding (LFW). This paper presents the fatigue behavior of dissimilar titanium alloys, Ti–6Al–4V (Ti64) and Ti–6Al–2Sn–4Zr–2Mo–0.1Si (Ti6242), joined by LFW with the aim of characterizing the stress versus number of cycles to failure (S-N) curves in both the low- and high-cycle fatigue regimes. Prior to fatigue testing, metallurgical characterization of the dissimilar alloy welds indicated softening in the heat-affected zone due to the retention of metastable β, and the typical practice of stress relief annealing (SRA) for alleviating the residual stresses was effective also in transforming the metastable β to equilibrated levels of α + β phases and recovering the hardness. Thus, the dissimilar alloy joints were fatigue-tested in the SRA (750 °C for 2 h) condition and their low- and high-cycle fatigue behaviors were compared to those of the Ti64 and Ti6242 base metals (BMs). The low-cycle fatigue (LCF) behavior of the dissimilar Ti6242–Ti64 linear friction welds was characterized by relatively high maximum stress values (~ 900 to 1100 MPa) and, in the high-cycle fatigue (HCF) regime, the fatigue limit of 450 MPa at 10⁷ cycles was just slightly higher than that of the Ti6242 BM (434 MPa) and the Ti64 BM (445 MPa). Fatigue failure of the dissimilar titanium alloy welds in the low-cycle and high-cycle regimes occurred, respectively, on the Ti64 and Ti6242 sides, roughly 3 ± 1 mm away from the weld center, and the transitioning was reasoned based on the microstructural characteristics of the BMs.     

Effect of Rod-like Structure on Fatigue Life,Short Surface Crack Initiation and Growth Characteristics of Extruded Aluminum Alloy A2024 (Analysis via Modified Linear Elastic Fracture Mechanics)

In the Al alloy A2024-T3 extruded material, a rod-like structure is generated parallel to the extrusion direction. In this study, the effects of rod-like structures on fatigue crack initiation and growth behavior were comprehensively investigated. Two types of specimens were used in a fatigue experiment, in which the direction of the load stress amplitude was parallel (specimen P) and perpendicular (specimen V) to the rod-like structure. Based on the experimental and analytical results, the following findings were obtained regarding the fatigue life, location of crack initiation, and fatigue crack growth behavior. Because the fatigue life of specimen P was longer than that of specimen V, it is inferred that the rod-like structure significantly affects the fatigue life. In specimen P, fatigue cracks were generated from the grain boundaries of the Al matrix. By contrast, in specimen V, cracks were generated from the Cu–Mg-based intermetallic compound in the Al matrix. In specimen P, fatigue cracks were more likely to propagate across the rod-like structure, which decreased the fatigue crack growth rate. In specimen V, fatigue cracks did not propagate across the rod-like structure; instead, they propagated through the Al matrix. Therefore, the fatigue crack growth resistance of specimen V was lower than that of specimen P. The relationship between the fatigue crack growth rate and the modified linear elastic fracture mechanics parameter could be used to predict the S–N curve (stress amplitude vs. fatigue life) and fatigue crack growth behavior. The predicted results agreed well with the experimental results.     

Fatigue Life Prediction of Machined Specimens with the Consideration of Surface Roughness

The fatigue strength and fatigue life of high-strength steels are greatly affected by their surface roughness. This study investigates the underlying mechanisms responsible for fatigue failure of the high-strength steel 42CrMo. Bending fatigue tests of stepped shafts with different levels of surface roughness were conducted to observe the fatigue live reduction affected by surface topography. Besides, the mechanical properties of 42CrMo and its strain–life relationship were established. Moreover, the analytical formulas to describe the stress concentration factor (SCF) and fatigue notch factor (FNF) induced by surface topography were introduced. To estimate the fatigue life of machined specimens with the consideration of surface roughness, the elastic portion of the total strain–life curve of the material was revised with the proposed analytical FNF imposed by surface topography. Comparisons between the estimated fatigue lives and experimentally obtained fatigue lives show that the effect of surface roughness on fatigue lives could be estimated effectively and conveniently by the proposed procedure.     

Parameter Interval Uncertainty Analysis of Internal Resonance of Rotating Porous Shaft–Disk–Blade Assemblies Reinforced by Graphene Nanoplatelets

This paper conducts a parameter interval uncertainty analysis of the internal resonance of a rotating porous shaft–disk–blade assembly reinforced by graphene nanoplatelets (GPLs). The nanocomposite rotating assembly is considered to be composed of a porous metal matrix and graphene nanoplatelet (GPL) reinforcement material. Effective material properties are obtained by using the rule of mixture and the Halpin–Tsai micromechanical model. The modeling and internal resonance analysis of a rotating shaft–disk–blade assembly are carried out based on the finite element method. Moreover, based on the Chebyshev polynomial approximation method, the parameter interval uncertainty analysis of the rotating assembly is conducted. The effects of the uncertainties of the GPL length-to-width ratio, porosity coefficient and GPL length-to-thickness ratio are investigated in detail. The present analysis procedure can give an interval estimation of the vibration behavior of porous shaft–disk–blade rotors reinforced with graphene nanoplatelets (GPLs).     

Creep–Fatigue Experiment and Life Prediction Study of Piston 2A80 Aluminum Alloy

In order to improve the reliability and service life of vehicle and diesel engine, the fatigue life prediction of the piston in a heavy diesel engine was studied by finite element analysis of piston, experiment data of aluminum alloy, fatigue life model based on energy dissipation criteria, and machine learning algorithm. First, the finite element method was used to calculate and analyze the temperature field, thermal stress field, and thermal–mechanical coupling stress field of the piston, and determine the area of heavy thermal and mechanical load that will affect the fatigue life of the piston. Second, based on the results of finite element calculation, the creep–fatigue experiment of 2A80 aluminum alloy was carried out, and the cyclic response characteristics of the material under different loading conditions were obtained. Third, the fatigue life prediction models based on energy dissipation criterion and twin support vector regression are proposed. Then, the accuracy of the two models was verified using experiment data. The results show that the model based on the twin support vector regression is more accurate for predicting the material properties of aluminum alloy. Based on the established life prediction model, the fatigue life of pistons under actual service conditions is predicted. The calculation results show that the minimum fatigue life of the piston under plain condition is 2113.60 h, and the fatigue life under 5000 m altitude condition is 1425.70 h.     

Effect of Graphene Nanoplatelets (GNPs) on Fatigue Properties of Asphalt Mastics

To investigate the effect of graphene on the fatigue properties of base asphalt mastics, graphene nanoplatelets (GNPs)-modified asphalt mastics and base asphalt mastics were prepared. A dynamic shear rheometer (DSR) was used to conduct the tests in the stress-controlled mode of a time-sweep test. The results showed that GNPs can improve the fatigue life of asphalt mastic. Under a stress of 0.15 MPa, the average fatigue life growth rate (ω¯) was 17.7% at a filler-asphalt ratio of 0.8, 35.4% at 1.0, and 45.2% at 1.2; under a stress of 0.2 MPa, the average fatigue life growth rate (ω¯) was 17.9% at a filler-asphalt ratio of 0.8, 25.6% at 1.0, and 38.2% at 1.2. The growth value (ΔT) of fatigue life of GNPs-modified asphalt mastics increased correspondingly with the increase of filler–asphalt ratio, the correlation coefficient R² was greater than 0.95, and the growth amount showed a good linear relationship with the filler–asphalt ratio. In the range of 0.8~1.2 filler–asphalt ratio, the increase of mineral powder can improve the fatigue life of asphalt mastics, and there is a good linear correlation between filler–asphalt ratio and fatigue life. The anti-fatigue mechanism of GNPs lies in the interaction between GNPs and asphalt, as well as its own lubricity and thermal conductivity.     

Behavior of Weld to S960MC High Strength Steel from Joining Process at Micro-Jet Cooling with Critical Parameters under Static and Fatigue Loading

The paper is focused on testing the weld of the S960MC steel produced at the micro-jet cooling under static and fatigue loading at critical parameters. This kind of material was in the form of a sheet with a thickness equal to 2 mm. The joint was obtained using three different types of welding wires: EDFK 1000, Union NiMoCr and Union X96 at the same parameters of the process. The joints were examined using non-destructive and destructive tests. The results from non-destructive experiments enable us to assess the quality of the welds directly before the joining process. In contrast, the destructive one allows following welds behavior under different loading conditions with their critical parameters. The bending experiments confirmed the good plastic properties of the weld, expressed by no cracks in the region tested in many variants of the joint manufactured. The results from static tests indicated a significant reduction of mechanical parameters of the weld in comparison to the base metal, expressed by 50% differences. Fatigue data have enabled us to follow the welding behavior at the increasing amplitude of axial stress up to fracture at constant amplitude value covering the following values of stress 650 MPa–100 MPa. Variations of total energy are presented at different values of several cycles up to fracture. Fracture regions are collected for analysis of the joint region features under cyclic loading. They have indicated differences in weld cracking depended on the stress level. Finally, the Wöhler S-N curve of the weld was determined, indicating the value of the fatigue limit of the weld tested, i.e., 100 MPa. The weld at the Union NiMoCr welding wire was indicated as the joint having the highest resistance on static and fatigue loadings.     

Effect of Surface Ultrasonic Rolling Treatment on Rolling Contact Fatigue Life of D2 Wheel Steel

A GPM-30 fatigue machine was used to investigate the influence of surface ultrasonic rolling (SURT) on the rolling contact fatigue (RCF) life of D2 wheel steel. The experimental results present that the RCF life of the grinding processing sample is 4.1 × 10⁵ cycles. During the RCF process, the flaking of the fine grain layer and high surface roughness of the grinding processing sample cause the production of RCF cracks. When the samples are treated by SURT with 0.2 MPa and 0.4 MPa, the RCF life is 9.2 × 10⁵ cycles and 9.6 × 10⁵ cycles, respectively. After SURT, the surface roughness of the samples is reduced, and a certain thickness of gradient-plastic-deformation layer and a residual-compressive-stress layer are produced. These factors lead to the improvement of the RCF property. However, when the static pressure increases to 0.6 MPa during SURT, the RCF life of the sample is reduced during RCF testing. The micro-cracks, which are formed during SURT, become the crack source and cause the formation of RCF cracks, decreasing of the RCF life.     

Effect of Ankle Torque on the Ankle–Foot Orthosis Joint Design Sustainability

The ankle joint of a powered ankle–foot orthosis (PAFO) is a prominent component, as it must withstand the dynamic loading conditions during its service time, while delivering all the functional requirements such as reducing the metabolic effort during walking, minimizing the stress on the user’s joint, and improving the gait stability of the impaired subjects. More often, the life of an AFO is limited by the performance of its joint; hence, a careful design consideration and material selection are required to increase the AFO’s service life. In the present work, a compact AFO joint was designed based on a worm gear mechanism with steel and brass counterparts due to the fact of its large torque transfer capability in a single stage, enabling a compact joint. Further, it provided an added advantage of self-locking due to the large friction that prevents backdrive, which is beneficial for drop-foot recovery. The design was verified using nonlinear finite element analysis for maximum torque situations at the ankle joint during normal walking. The results indicate stress levels within its design performance; however, it is recommended to select high-grade structural steel for the ankle shaft as the highest stresses in AFO were located on it.     

Vortex Flow on the Surface Generated by the Onset of a Buoyancy-Induced Non-Boussinesq Convection in the Bulk of a Normal Liquid Helium

The onset of the Rayleigh–Benard convection (RBC) in a heated from above normal He-I layer in a cylindrical vessel in the temperature range T_λ < T ≤ T_m (RBC in non-Oberbeck–Boussinesq approximation) is attended by the emergence of a number of vortices on the free liquid surface. Here, T_λ = 2.1768 K is the temperature of the superfluid He-II–normal He-I phase transition, and the liquid density passes through a well-pronounced maximum at T_m ≈ T_λ + 6 mK. The inner vessel diameter was D = 12.4 cm, and the helium layer thickness was h ≈ 2.5 cm. The mutual interaction of the vortices between each other and their interaction with turbulent structures appeared in the layer volume during the RBC development gave rise to the formation of a vortex dipole (two large-scale vortices) on the surface. Characteristic sizes of the vortices were limited by the vessel diameter. The formation of large-scale vortices with characteristic sizes twice larger than the layer thickness can be attributed to the arising an inverse vortex cascade on the two-dimensional layer surface. Moreover, when the layer temperature exceeds T_m, convective flows in the volume decay. In the absence of the energy pumping from the bulk, the total energy of the vortex system on the surface decreases with time according to a power law.     

Failure Load and Fatigue Behavior of Monolithic Translucent Zirconia,PICN and Rapid-Layer Posterior Single Crowns on Zirconia Implants

This laboratory study aimed to evaluate the thermo-mechanical fatigue behavior and failure modes of monolithic and rapid-layer posterior single-crowns (SCs) supported by zirconia implants. Methods: 120 all-ceramic crowns supported by one-piece zirconia implants (ceramic.implant; vitaclinical) were divided into five groups (n = 24 each): Group Z-HT: 3Y-TZP monolithic-zirconia (Vita-YZ-HT); Group Z-ST: 4Y-TZP monolithic-zirconia (Vita-YZ-ST); Z-XT: 5Y-TZP monolithic-zirconia (Vita-YZ-XT); Group E: monolithic-polymer-infiltrated ceramic network (PICN,Vita-Enamic); Group RL (rapid layer): PICN-“table-top” (Vita-Enamic), 3Y-TZP-framework (Vita-YZ-HT). Half of the specimens of each group (n = 12) were exposed to fatigue with cyclic mechanical loading (F = 198N, 1.2-million cycles) and simultaneous thermocycling (5–55 °C). Single-load-to-failure testing (Z010, Zwick) was performed for all specimens without/with fatigue application. Data analysis was performed using ANOVA, Tukey’s post-hoc test, two-sample t-test and Bonferroni correction (p < 0.05). Results: All specimens survived fatigue exposure. Significant differences in failure loads were detected among groups (p ≤ 0.004). Materials Z-HT and Z-ST showed the highest failure loads followed by Z-XT, RL and E. The influence of fatigue was only significant for material RL. Conclusions: All types of tested materials exceeded clinically acceptable failure load values higher than 900N and can be recommended for clinical use. Z-HT and Z-ST appear to be highly reliable towards fatigue. Rapid-layer design of PICN and YZ-HT might be an interesting treatment concept for posterior implant SCs.     

Investigation of Changes in Fatigue Damage Caused by Mean Load under Block Loading Conditions

The literature in the area of material fatigue indicates that the fatigue properties may change with the number of cycles. Researchers recommend taking this into account in fatigue life calculation algorithms. The results of simulation research presented in this paper relate to an algorithm for estimating the fatigue life of specimens subjected to block loading with a nonzero mean value. The problem of block loads using a novel calculation model is presented in this paper. The model takes into account the change in stress–strain curve parameters caused by mean strain. Simulation tests were performed for generated triangular waveforms of strains, where load blocks with changed mean strain values were applied. During the analysis, the degree of fatigue damage was compared. The results of calculations obtained for standard values of stress–strain parameters (for symmetric loads) and those determined, taking into account changes in the curve parameters, are compared and presented in this paper. It is shown that by neglecting the effect of the mean strain value on the K′ and n′ parameters and by considering only the parameters of the cyclic deformation curve for ε_m = 0 (symmetric loads), the ratio of the total degree of fatigue damage varies from 10% for ε_a = 0.2% to 3.5% for ε_a = 0.6%. The largest differences in the calculation for ratios of the partial degrees of fatigue damage were observed in relation to the reference case for the sequence of block n₃, where ε_m = 0.4%. The simulation results show that higher mean strains change the properties of the material, and in such cases, it is necessary to take into account the influence of the mean value on the material response under block loads.     

Effect of Sandblasting on Static and Fatigue Strength of Flash Butt Welded 75Cr4 Bandsaw Blades

The aim of the research presented in this article is analysis of the effect of the surface treatment method on the static and fatigue strength of flash butt welded bandsaw blades. A 1-mm-thick 75Cr1 cold-work tool steel sheet used for bandsaw blades was used as the test material. Fractographic studies of the fatigue fractures and fractures formed in static tests were also carried out. The static strength tests showed sandblasting the weld surface had no significant effect on the load capacity of the joint. However, the sandblasted specimens showed a higher repeatability of the load capacity (lower standard deviation). In the case of both analyzed sample variants of specimens, sandblasted and non-sandblasted, the number of cycles at which the sample was damaged decreases with the percentage increase of the stress amplitude. When loading the samples with a stress amplitude value in the range between 400 and 690 MPa, sandblasting of the weld surface increased the average value of destructive cycles by about 10–86% (depending on the stress amplitude) compared to non-sandblasted joints. The sandblasting process introduces compressive stresses in the surface layer of the welds, therefore the variable tensile load acting on the sample requires a greater number of cycles before the fatigue cracks initiate and propagate. In the case of all specimens, a ductile fracture was observed. It was also found that, regardless of the variable stress amplitude, sandblasting has a positive effect on reducing the standard deviation of fatigue test results.     

Fatigue Properties of Hot-Dip Galvanized AISI 1020 Normalized Steel in Tension–Compression and Tension–Tension Loading

Since hot-dip galvanizing causes a heat effect on cold-worked steel substrate and produces a coating layer comprised of distinct phases with varying mechanical properties, the fatigue mechanism of hot-dip galvanized steel is very complex and hard to clarify. In this study, AISI 1020 steel that has been normalized to minimize susceptibility to the heat effect was used to clarify the effect of the galvanizing layer on the tensile and fatigue properties. The galvanizing layer causes a reduction in the yield point, tensile strength, and fatigue strength. The reduction in the fatigue strength was more significant in the high cycle fatigue at R = 0.5 and 0.01 and in the low cycle fatigue at R = 0.5. The galvanizing layer seems to have very little effect on the fatigue strength at R = −1.0 in the low and high cycle fatigue. Since the fatigue strengths at R = 0.01 and −1.0 in the low cycle fatigue were strongly related to the tensile strength of the substrate, the cracking of galvanized steel was different than that of non-galvanized steel. The fatigue strength of galvanized steel at R = 0.5 dropped remarkably in the low cycle fatigue in comparison to the non-galvanized steel, and many cracks clearly occurred in the galvanizing layer. The galvanizing layer reduced the fatigue strength only under tension–tension loading. We believe that the findings in this study will be useful in the fatigue design of hot-dip galvanized steel.     

Process–Structure–Property Relationships of Copper Parts Manufactured by Laser Powder Bed Fusion

The process–structure–property relationships of copper laser powder bed fusion (L-PBF)-produced parts made of high purity copper powder (99.9 wt %) are examined in this work. A nominal laser beam diameter of 100 μm with a continuous wavelength of 1080 nm was employed. A wide range of process parameters was considered in this study, including five levels of laser power in the range of 200 to 370 W, nine levels of scanning speed from 200 to 700 mm/s, six levels of hatch spacing from 50 to 150 μm, and two layer thickness values of 30 μm and 40 μm. The influence of preheating was also investigated. A maximum relative density of 96% was obtained at a laser power of 370 W, scanning speed of 500 mm/s, and hatch spacing of 100 μm. The results illustrated the significant influence of some parameters such as laser power and hatch spacing on the part quality. In addition, surface integrity was evaluated by surface roughness measurements, where the optimum Ra was measured at 8 μm ± 0.5 μm. X-ray photoelectron spectroscopy (XPS) and energy-dispersive X-ray spectroscopy (EDX) were performed on the as-built samples to assess the impact of impurities on the L-PBF part characteristics. The highest electrical conductivity recorded for the optimum density-low contaminated coils was 81% IACS.