A wide process space with laser power (P) of 50 ~ 400 W and scanning speed (s) of 50 ~ 2400 mm/s with the energy density (ED) range of 93–556 J/mm3 has been employed to fabricate NiTi alloy using laser powder bed fusion (LPBF). The optimal process window for near-full dense materials free of geometrical and metallurgical defects was determined. The characteristics of microstructures and compressive behaviors were comprehensively investigated. The results have shown that the process combinations of “high P + low s” and “high P + high s” are prone to bulging and warping defects due to rapid heating and cooling, respectively. A combination of “low P + low s” produces a relatively shallow melt pool without keyhole formation even at ED as high as 556 J/mm3. The austenite-martensite phase transition temperature (TTs) variations of ~80℃ were obtained with the process window free of porosity. The pre-existing martensite lath probably formed by plastic distortion (bulging) was responsible for the lowest critical stress of induced martensite (σSIM). The texture and nano-sized NiTi2/Ni2Ti4Ox precipitates also contribute to the variation of σSIM and residual strain among the samples with the same level of TTs upon compressive loading.
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