Optimization of selective laser melting parameters of Ti6Al4V alloys lattice structures utilizing taguchi method and grey relational analysisOA

Background: This study focuses on the fabrication and optimization of Ti6Al4V alloy latticestructures produced by the Selective Laser Melting (SLM) process. Such structures areincreasingly used in biomedical implants due to their potential to match the mechanicalproperties of human bone. Key features influencing their performance include porosity ratio,surface roughness, elastic modulus, and yield strength. Achieving a balance between theseparameters is essential for ensuring both mechanical integrity and biological compatibility.Methods: The Taguchi method integrated with Grey Relational Analysis (GRA) wasemployed to optimize the SLM process parameters—laser power (160-240 J), scanningspeed (1000-1500 mm/min), and hatch spacing (0.06-0.12 mm). The optimization aimed toproduce lattice structures with properties closely resembling human bone. Experimentaltrials were conducted to evaluate the effects of these parameters on porosity, surfaceroughness, elastic modulus, and yield strength, followed by statistical and relational analysisto determine the optimal configuration. Results: The results revealed that higher scanningspeed, wider hatch spacing, and lower laser power increased the porosity ratio compared toCAD models. A strong inverse relationship was observed between porosity and both yieldstrength and elastic modulus. Increasing laser power substantially reduced surfaceroughness. Through Taguchi-GRA optimization, the optimal parameter combination wasdetermined as laser power of 240 J, scanning speed of 1250 mm/min, and hatch spacing of0.06 mm. Under these conditions, the obtained values were: modulus of elasticity (0°) = 20GPa, modulus of elasticity (90°) = 18.874 GPa, yield strength (0°) = 265 MPa, yieldstrength (90°) = 260 MPa, porosity = 48.565%, and surface roughness = 6.223 μm.Conclusion: The optimized SLM parameters successfully produced Ti6Al4V latticestructures with mechanical and morphological characteristics compatible with human bone.The study highlights the critical balance between process parameters and structuralfeatures, providing a systematic approach for tailoring lattice structures for biomedicalapplications through Taguchi and GRA-based optimization.