The Paton Welding Journal, 2026, №07

2026 №07 (03)

DOI of Article 10.37434/tpwj2026.07.04

2026 №07 (05)

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The Paton Welding Journal, 2026, #7, 21-25 pages

Features of porosity formation in Ti–6Al–4V alloy produced by selective laser melting

S.V. Adzhamskyi^1,2, R.V. Podolskyi^2,3, Z.V. Sazanishvili⁴, G.A. Kononenko^2,3,4

¹Institute of Transport Systems and Technologies of the NASU 5 Pysarzhevskoho Str., 49000, Dnipro, Ukraine
²LLC “Additive laser technology of Ukraine” 105 Heavenly Hundred Avenue, 65104, Odesa, Ukraine E-mail: rostislavpodolskij@gmail.com
³Iron and Steel Institute of Z.I. Nekrasov of the NASU 1 Akademika Starodubova Sq., 49000, Dnipro, Ukraine
⁴National Technical University “Dnipro Polytechnic” 19 Prosp. Dmytra Yavornytskoho, 49005, Dnipro, Ukraine

Abstract
This study investigates the features of microstructure formation and pore geometry in samples of the Ti–6Al–4V titanium alloy manufactured using selective laser melting under optimal process conditions. The aim of the study is to identify the patterns of SLM process influence on the nature of pore formation and the spatial distribution of pores relative to the laser scanning trajectories. The main objectives of the work are to analyze the material’s microstructure, quantitatively assess porosity, determine the size, shape, clustering, and spatial distribution of pores, and identify the mechanisms of their formation. The study was conducted on samples produced at the recommended selective laser melting parameters: laser power 195 W, scanning speed 1000 mm/s, track spacing 0.12 mm, and layer thickness 40 μm. Optical microscopy was used to study the microstructure, and the quantitative analysis of porosity, including the determination of the area, equivalent diameter, sphericity coefficient, and distribution density of pores, was performed using ImageJ software. It has been established that the pores have different morphologies and form both individual inclusions and local clusters, spatially associated with track boundaries and overlap zones. For the first time, a correlation has been demonstrated between the sphericity of pores and their location relative to the track structure: more spherical pores are localized predominantly in the central zones of the melt pools, whereas elongated and irregularly shaped pores are concentrated near the scan boundaries. The results obtained deepen the understanding of the mechanisms of pore formation in Ti–6Al–4V during SLM and can be used for the further optimization of additive manufacturing process parameters.
Keywords: SLM technology, Ti–6Al–4V, pores, discreteness, microstructure

Received: 26.02.2026
Received in revised form: 28.04.2026
Accepted: 14.07.2026

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Suggested Citation

S.V. Adzhamskyi, R.V. Podolskyi, Z.V. Sazanishvili, G.A. Kononenko (2026) Features of porosity formation in Ti–6Al–4V alloy produced by selective laser melting. The Paton Welding J., 07, 21-25. https://doi.org/10.37434/tpwj2026.07.04

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