In this study, macro-scale thermal simulation of the laser powder bed fusion (LPBF) process is employed to predict and limit geometry-induced overheating of complex Ti6Al4V components. First, the overheating effect is reproduced in tensile specimens. Overheating is found to increase the local oxygen content by almost 80% and lower the elongation at break by over 70% in overheated regions. By employing macro-scale thermal simulations, an automated routine is developed to efficiently optimize the L-PBF process to prevent local overheating. Variable interlayer wait times are numerically optimized to allow cooling of the material without adding manufacturing time where this is not required. In this way, local overheating can successfully be prevented resulting in a more homogeneous temperature distribution during the L-PBF process. This method was found to fully restore the mechanical properties in geometries prone to overheating, resulting in more homogeneous and predictable Ti6Al4V components.
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