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Meeting 2026 TMS Annual Meeting & Exhibition
Symposium Additive Manufacturing Fatigue and Fracture
Presentation Title Hybrid Laser Powder Bed Fusion Processing Via Femtosecond Lasers to Enhance Surface Finish and Fatigue Performance
Author(s) David Stone, Timothy Osborn, Ben Naguy, Jared Speltz, Matt Krug
On-Site Speaker (Planned) David Stone
Abstract Scope Metal additive manufacturing (AM) via laser powder bed fusion (LPBF) currently requires post processing to improve surface finish and fatigue performance, and to create features finer than print resolutions. Interior surfaces can be difficult or impossible to refinish. UDRI has built an industrial hybrid additive, LBPF, system that includes both a 500W CW laser for additive manufacturing, and a 100W femtosecond laser for in-process surface machining/manipulation. Utilizing this hybrid (additive-subtractive) capability, processing strategies are investigated for improvement of as-printed fatigue performance and fine feature resolution. The effects of in-process surface machining on fatigue-relevant features in Nickel alloys are characterized via microscopy and fatigue testing. This work presents a pathway to in-process surface roughness control and fine feature manufacturing in AM.
Proceedings Inclusion? Planned:
Keywords Additive Manufacturing, Process Technology, High-Temperature Materials

OTHER PAPERS PLANNED FOR THIS SYMPOSIUM

3D Fatigue State Matrix (3D-FSM) with Active Elements Communication for Multi-Scale Fatigue Life Prediction in Metal Additive Manufacturing
Advanced Fatigue Data Assessment through Fatigue Limit Software
Anisotropic Creep and Fatigue Behavior of Laser Powder Bed Fusion 316H
Defect and Local Microstructure Effects on Fatigue Behavior in LPBF Ti-6Al-4V: Insights from Fractographic Analysis
Defect Categories and Fatigue Prediction in Laser Powder Bed Fusion
Determining the Interactive Role of Pore and Grain Structures on Fracture Behavior of Additive Manufactured Metals Using 3D Microstructure Measurements and Numerical Modeling
Effect of Post-heat Treatment on IN718 Alloy Fabricated Using Three Different Additive Manufacturing (AM) Routes
Equivalency Framework Utilizing Multiple Additive Manufacturing Systems
F-3: Bio-inspired Composites with Hierarchically-Structured Fractal Interfaces: Design, Additive Manufacturing, Mechanical Testing, and Toughening Mechanisms
F-4: Towards a Universal Scaling Law for Predicting Contact Angle in Laser Powder Bed Fusion
F-5: Fatigue and Tensile Properties of Ti-6Al-4V Fabricated with Wire-feed Electron Beam Additive Manufacturing
F-7: Multi-Material Laser Powder Bed Fusion of Stainless Steel–Copper Structures: Interfacial and Thermal-Structural Performance
F-8: Process Optimization of Boron-Alloyed 316L Stainless Steel Using Taguchi Design and CrB Phase Analysis Through Image Processing
F-9: Residual Stress Characterization in Additively-Manufactured Parts Using a Femtosecond Laser System
Factors Affecting Fatigue- and Toughness-based Processing Windows for LPBF Ti-6Al-4V
Factors Controlling Residual Stress Formation in Laser Powder Bed Fusion Fabricated AlSi10Mg and Ti6Al4V
Fatigue Lifetime Prediction Using a Continuum Damage Modeling Approach for Porosity Induced Failures in Additively Manufactured Materials
High-Strength Additively Manufacturable Al-Zr-Er-Ni Alloys with High As-Built Ductility
High-Temperature Fatigue Behavior of Additively Manufactured Aluminum Alloys
High-Throughput Characterization of the Effects of Surface Treatments on Additively Manufactured Metals Using Vision Transformers
High Throughput Characterization of Additively Manufactured Materials with Multi-Gage Resonance Fatigue
Hybrid Laser Powder Bed Fusion Processing Via Femtosecond Lasers to Enhance Surface Finish and Fatigue Performance
Influence of Surface Topography on Fatigue Behaviour of As-Built Thin-Walled Laser Wire Directed Energy Deposited (LW-DED) AISI 316L Stainless Steel
Influence of Textured Microstructures on the Strength and Fatigue Resistance of AlSi10Mg LPBF Specimens
Microstructure and Mechanical Control of Metal AM for Critical Applications
Modeling Fatigue Short Crack Propagation in Polycrystalline Microstructures of Additively Manufactured Alloys Using Coupled Crystal Plasticity-Phase Field Model
On the Fracture Toughness and Fatigue Crack Growth Resistance in Laser Powder Bed Fusion Fabricated AlSi10Mg
On the Structural Integrity of AlSi40 Alloy Processed by Laser-Based Powder Bed Fusion
Probabilistic Safe Life Modeling of Laser Powder Bed Fusion Additively Manufactured Ti-6Al-4V Using Extreme Value Statistics with Uncertainty
Promoting Damage Tolerance by Apt Microstructure Design in Additive Manufacturing
Quantifying the Fatigue Criticality of Microstructual Features in L-PBF IN718
Role of Volumetric Defects and Microstructure on the Fatigue Behavior of Additively Manufactured Inconel 718: An Experimental Study
The Effects of Microalloying on the High-Temperature Creep and Fracture Properties of AM Ni-Based Superalloys
Understanding Fatigue Crack Initiation and Growth in an Additively Manufactured Cu Based Alloy
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