Scalable laser powder bed fusion processing of nitinol shape memory alloy

Ian McCue, Christopher Peitsch, Tim Montalbano, Andrew Lennon, Joseph Sopcisak, Morgana M. Trexler, Steven Storck*

*Corresponding author for this work

Research output: Contribution to journalArticlepeer-review

3 Scopus citations


The authors report on pulsed laser powder bed fusion fabrication of nitinol (NiTi) shape memory materials. The authors first performed single-track laser parameter sweeps to assess melt pool stability and determine energy parameters and hatch spacing for larger builds. The authors then assessed the melt pool chemistry as a function of laser energy density and build plate composition. Brittle intermetallics were found to form at the part/build plate interface for both N200 and Ti-6-4 substrates. The intermetallic formation was reduced by building on a 50Ni-50Ti substrate, but delamination still occurred due to thermal stresses upon cooling. The authors were able to overcome delamination on all substrates and fabricate macroscopic parts by building a lattice support structure, which is both compliant and controls heat transfer into the build plate. This approach will enable scalable fabrication of complex NiTi parts.

Original languageEnglish (US)
Pages (from-to)1214-1220
Number of pages7
JournalMRS Communications
Issue number4
StatePublished - 2019
Externally publishedYes

ASJC Scopus subject areas

  • Materials Science(all)


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